Post on 26-Jul-2016
description
CHINESE OVERVIEW
REFRACTORIES
SHANDONG HUAPENG - CHAIRMAN INTERVIEW
WWWGLASS-INTERNATIONALCOM
I N T E R N A T I O N A L
March 2016mdashVol39 No3
A GLOBAL REVIEW OF GLASSMAKING
Glass International M
arch 2016
Thin Glass
Tableware
Container Glass
Float Glass
Fibre Glass
Our fresh breeze for all types of glass production
GI Cover-marchindd 1 3916 259 PM
To make glass better
put us in the mix
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Contents
Glass International March 2016
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1
March 2016 Vol39 No3
2 Editorrsquos Comment
5 International news
13 Company overview Shandong Huapeng A Chinese group with global plans
17 Chinese overview Chinarsquos container industry set to rise to higher peaks 20 Company profile FERVER Federation proves that glass recycling is not a waste of time
Supplier profile Zippe24 A family affair
27 Lubricants Swabbing Robot lubricant success
28 History British Glass30 Small is beautiful
Case study Verallia Bad Wurzach32 Verallia installs synchronous reluctance technology
Refractories37 Recycling refractories40 Analysis of glass defect compositions from AZS refractory
Inspection44 Improving the quality of hollow glass through inspection
Plant technology46 A production monitoring solution
Front cover image wwwemede
Plus find us on Linked-In and Twitter
wwwglass-internationalcom
Glass_Int 32
20
24
13
CHINESE OVERVIEW
REFRACTORIES
SHANDONG HUAPENG - CHAIRMAN INTERVIEW
WWWGLASS-INTERNATIONALCOM
I N T E R N A T I O N A L
March 2016mdashVol39 No3
A GLOBAL REVIEW OF GLASSMAKING
Glass International M
arch 2016
Thin Glass
Tableware
Container Glass
Float Glass
Fibre Glass
Our fresh breeze for all types of glass production
Contents FEBindd 1 31616 941 AM
Editorrsquos comment
Glass International March 2016
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2
Itrsquos been an interesting month for me mostly spent in a car or train travelling to several meetings with prominent
suppliers and leading fi gures of the glass manufacturing industry
These people are at the forefront of our business and represent a variety of sub sectors They travel a lot speak to plenty of people and generally have their fi nger on the pulse of the industry
Among our varied chats ndash which are always a pleasure ndash one concern alone stood out the lack of young people enter-ing the industry
The glass industry is not an attractive one to youngsters Glass plants are hot noisy and dirty places Other industries with minimalistic air-conditioned offi c-es and a glamorous end product such as the automotive industry in the UK are regarded as cooler and cutting edge
One correspondent told me that the last innovation in the glass industry was 30 years ago with the introduction of the NNPD process Where will the new ideas come from if young talent is snapped up by other industries
It is not all hopeless Projects such as British Glassrsquo Glass Academy have raised the profi le of glass in schools and encour-aged apprentices to pursue a career in the industry Other national associations should follow its lead
Glass is still regarded as a desirable industry in developing nations such as
China India and the Philippines Young less weathered faces were prominent at events such as Glasspex in India the AFGM event in the Philippines and Glass-man in Mexico
The exchange of knowledge and new ideas is as important as ever If young peo-ple are opting to forge careers elsewhere glass must make use of the talent it has if it is to retain its leading position
The forthcoming Glassman Middle East conference is one such event where suppliers and manufacturers will present the latest trends and innovations
The Middle East with its fl ourishing youthful population is an ideal market in terms of attracting young people to glass It should follow the lead of the regionrsquos aluminium industry which has plenty of fresh-faced graduates working in it
Given the recent boom in activity in the MENA region including the lifting of trade sanctions in Iran the free to attend conference has attracted attention from manufacturers keen to visit the hollow glass industryrsquos most prominent suppli-ers The event will welcome the Director of Iranrsquos Noritazeh and the Operations Director of Frigoglassrsquos glass manufactur-ing division as keynote speakers
Greg MorrisEditorgregmorrisquartzltdcom
Greg Morris
Where have all the young people gone
wwwglass-internationalcom
Quartz Glass Portfolio
Editor Greg MorrisTel +44 (0)1737 855132Email gregmorrisquartzltdcom
Assistant Editor Sally LoveTel +44 (0)1737 855154Email sallylovequartzltdcom
Designer Annie BakerTel +44 (0)1737 855130Email anniebakerquartzltdcom
Sales Director Ken ClarkTel +44 (0)1737 855117Email kenclarkquartzltdcom
Sales Manager Jeremy FordreyTel +44 (0)1737 855133Email jeremyfordreyquartzltdcom
Production Executive Martin LawrenceManaging Director Steve Diprose
Chief Executive Offi cer Paul Michael
Subscriptions Elizabeth BarfordTel +44 (0)1737 855028 Fax +44 (0)1737 855034Email subscriptionsquartzltdcom
Published by Quartz Business Media LtdQuartz House 20 Clarendon Road Redhill Surrey RH1 1QX UKTel +44 (0)1737 855000 Fax +44 (0)1737 855034 Email glassquartzltdcomWebsite wwwglass-internationalcom
Glass International (ISSN 0143-7838) (USPS No 020-753) is published 10 times per year by Quartz Business Media Ltd and distributed in the US by DSW 75 Aberdeen Road Emigsville PA 17318-0437 Periodicals postage paid at Emigsville PA POSTMASTER send address changes to Glass International co PO Box 437 Emigsville PA 17318-0437
Offi cial publication of Abividro - the Brazilian Technical Association of Automatic Glass
Industries
Member of British Glass Manufacturersrsquo Confederation
China National Association for Glass Industry
United National Council of the glass industry (Steklosouz)
Glass International annual subscription rates including Glass International DirectoryFor one year UK pound164 all other countries pound231For two years UK pound295 all other countries pound416Airmail prices on request Single copies pound45
Glass International Directory 2015 editionUK pound206 all other countries pound217
Printed in UK byPensord Tram Road Pontlanfraith BlackwoodGwent NP12 2YA UK
copy Quartz Business Media Ltd 2015ISSN 0143-7838
Monthly journal for the industry worldwide
Directory 2015Annual international reference source
Glassman specialist exhibitions rotate between America Asia and Europe
wwwglass-internationalcom
China National Association for Glass Industry
Comment marchindd 1 31116 1235 PM
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Bucher Emhart Glass The future of glassmaking technology delivered today
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IS machine AIS machine
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International News
Glass International March 2016
5
Technology suppliers sign up for Middle East hollow glass event
NEWS IN BRIEF
Vitro sales boosted 22Growth in its container and flat glass businesses helped Vitro grow sales by 22
The Mexican company reported that the growth in the construction and automotive sectors as well as strong export and domestic sales had boosted business in the final quarter of 2015
Consolidated net sales increased 222 to US$229 million in the quarter it reported in its quarter four 2015 financials
Vitro CEO Mr Adrian Sada Cueva said ldquoThe strong dynamics of the construction market driven by shortages in Mexico and the economic recovery in the US coupled with the acquisition of new customers and increased exports of glass for the automotive sector and strong sales volumes in the pharmaceutical industry were the main factors that boosted sales this quarterrdquo
Frigoglass terminates GZI sale Frigoglass has terminated its agreement to sell its glass business in Dubai and Nigeria to GZ Industries (GZI)
The agreement was signed with GZI in May 2015 but a condition of the terms was not met GZI did not secure the necessary level of debt financing for the acquisition as a result of a change in regulations that restricts the ability to leverage Beta Glass and the adverse economic conditions in Nigeria
Amended offers were made by GZI but these were declined by Frigoglassrsquo Board of Directors
PPG sells PGW stakePPG is to sell 40 of its stake in Pittsburgh Glass Works (PGW)
The sale is in connection with LKQ Corporationrsquos plan to buy PGW which is expected to be completed by the end of the second quarter this year
PPG has held a minority interest in PGW since 2008 when it completed the sale of its automotive glass and services business to PGW
Several of the hollow glass in-dustryrsquos leading technology suppliers have confirmed their presence at the Glassman Mid-dle East event
German company Penneka-mp and UK group Electroglass have each taken a booth at the exhibition
They will be joined by French inspection group Tia-ma and Anderman Ceramics who will both present papers at the parallel conference
Pennekamp manufactures equipment for thermal pro-cesses (lehrs) as well as other
product areas within the glass industry
Electroglass has been in-volved in electric glass melt-ing technology since 1976 Its core activities are the develop-ment design engineering and supply of electric glass melting and conditioning systems and related equipment
Tiama is a provider of in-spection solutions for the hollow glass industry and will provide an update about its vi-sion product range
Anderman Ceramicsrsquo Gary Hateley will present a paper
titled Supplying refractory in-sulation for furnace linings
Glassman Middle East is a free to attend exhibition and conference dedicated to the hollowcontainertablewarespeciality glass sectors
It takes place on May 10 and 11 in Abu Dhabi UAE and vis-itors will include glass man-ufacturers from the region associations and technology suppliers
For more information visit wwwglassmaneventscommid-east
Iranian manufacturer Noritazeh confirmed as keynote speakerIranian tableware manufac-turer Noritazeh has been con-firmed as a keynote speaker at the Glassman Middle East hol-low glass conference
Noritazehrsquos Director Saeed
Kalafchi will give a 20-min-ute overview of the Iranian glass industry and provide an update on Noritazeh and its recent developments
Other speakers at the hol-
low glass conference include glass container manufacturer Frigoglass inspection compa-ny Tiama Pneumofore IRF Europa and French refracto-ries group Sefpro
Interglass and Pennekamp form LATAM partnership
Mexican group Interglass has formed a partnership with German lehrs company Pen-nekamp
The new partnership will see Interglass introduce and push Pennekamprsquos range of prod-ucts and equipment through-out the entire LATAM region
Jose Luis Velez Interglass Managing Director said ldquoWersquore very optimistic about
the success that this collabora-tion will bring to both compa-nies as Pennekamprsquos top tech-nology perfectly complements our solutions portfolio
ldquoWe are sure that this new partnership will be very pros-perous and that it will main-tain us on the right track to lead the LATAM market on be-half of all the companies that we represent and work withrdquo
March newsindd 1 31116 210 PM
International News
Glass International March 2016
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6
NEWS IN BRIEF
Borosilicate glassrsquo 125th anniversaryExactly 125 years ago Otto Schott the founder of the technology group Schott discovered borosilicate glass and created the basis for high-tech applications in the 21st century
The glass is used in a variety of applications from streaming of sports events to high-tech material research These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors
Thai Glass forms partnership with XparThai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry
The partnership is the crown on the co-operation which started two years ago between TGI which is the container glass manufacturing subsidiary of Berli Jucker in Thailand and Xpar Vision based in The Netherlands
The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera The trial was executed at the TGI production facility at Saraburi With the IR-D camera system all bottles are inspected in real time to detect critical defects
Libbey reports 35 drop in sales in 2015US tableware manufacturer Libbey reported a full year sales drop of 35 in 2015 compared to the prior year
In its full year financials for 2015 it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada
It said sales performance in the US and Canada last year was led by a 75 increase in sales within the segmentrsquos foodservice channel
For 2016 Libbey forecast a sales growth of 1 from $8223 million to $830 million
Ground clearing begins at Ethiopian bottling plantAtlasrsquo 100 owned subsid-iary East Africa Packaging Holdings (lsquoEAPHrsquo) is building a glass bottle manufacturing facility 45km north of Ethio-piarsquos capital Addis Ababa
The plant will have the ca-pacity to produce 105 million 330ml bottles a year
Named the lsquoChancho Pro-jectrsquo Atlas has commenced ground clearing at the site and held a ceremony to com-memorate the event (pictured with Atlasrsquo CEO Carl Esprey pictured second from left)
Commissioning of the fa-cility has been scheduled for 2018 with full production tar-geted for early 2019
Levelling of the 55 acre site has begun and the topsoil has been stripped
The Chancho Project site is located in an established in-dustrial area that is serviced by excellent road infrastruc-ture as well as power
Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropri-ate grades of silica sand and
limestone are available in de-posits 30km away from the site
An initial pre-feasibility study was completed at the Chancho Project and re-turned positive results
A full feasibility study is now being conducted in tandem with local and internation-al engineering consultants which is close to completion
The total capital expend-iture is estimated at US$42 million to be funded on a staged basis by a mixture of debt from local development banks other debt providers
industrial partners and equityFor the last five years due to
increased consumer demand and a young demographic Ethiopia has been attracting investment from internation-al beverage companies with more than $500 million in-vested to date
Beer production has been growing at a CAGR of 143 over the last 14 years with an additional 47 capacity cur-rently under construction
The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports
Record year for UK electric melting specialistUK-based electric melting spe-cialist Electroglass has report-ed a ten-year record in its 2015 results
ldquoDespite uncertainty and slow-down in a number of world markets we have had an excellent yearrdquo said Managing Director Richard Stormont
ldquoAll-electric furnace and forehearths projects for fluo-ride opal tableware glass in south Asia in particular have been significant contributors
to this along with borosili-cate electric forehearths work in the USA gas-to-electric soda-lime forehearth conver-sions in South Korea electric boosting projects in Indonesia and elsewhere and contin-uing development and sales of our Precision Control Bub-bling Systems
ldquoAlso holding up well are sales of hardware notably the Molycool and Vertical Splash-guard ranges of electrode
holders and our dry-type fore-hearth electrodesrdquo he added
ldquoThe rest of 2016 sees the commissioning of several re-cently supplied systems and work is expected to start on a number of significant new projects for the companyrdquo
Electroglass will be exhib-iting at the upcoming Glass-man Middle East show in Abu Dhabi on the 10th and 11th May
March newsindd 2 31116 210 PM
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
+ TECHNOLOGY OMCO uses tailored technology to weld and machine moulds plungers and neck rings
+ FLEXIBILITY OMCO uses efficient manufacturing processes enabling quick turnarounds for urgent jobs
+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
= QUALITY PROMPTLY DELIVERED AT A COMPETITIVE PRICE
MOULDSHOPS OMCO BELGIUM I OMCO AUSTRIA I OMCO UK I OMCO CROATIA I OMCO ISTANBUL I OMCO ROMANIA FOUNDRIES OMCO BELGIUM I OMCO SLOVENIA
OMCOLEADING MOULD MAKERTO THE GLASS WORLD
International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
Tomorrows Technology Today
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FIC - Cube ad 2016 20216 1200 Page 1
G L A S S Q U A L I T YFives is a leading provider of glass technologies for the most demanding applications ultra-thin automotive pharmaceutical fiber solar crystal and speciality glass We contractually guarantee the productivity and environmental performance of your plant for secured profitability of your investmentWith over 60 years of experience in the glass industry Fives designs engineers manufactures installs tests and commissions glass equipment in a wide range of glass processes and applications all over the worldTrust Fives professionals to enhance your plantrsquos performance and competitiveness and to optimize your investmentglassfivesgroupcom wwwfivesgroupcom
FIVES PRIUMreg TECHNOLOGY THE ULTIMATE ADDED VALUE TO YOUR INVESTMENT
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Glass International March 2016
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A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
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GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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nati
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com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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28
Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
distributors are offered with guarantees covering temperature stability thermal homogeneity and
fuel consumption
Are yours
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
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GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
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competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
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Contents
Glass International March 2016
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1
March 2016 Vol39 No3
2 Editorrsquos Comment
5 International news
13 Company overview Shandong Huapeng A Chinese group with global plans
17 Chinese overview Chinarsquos container industry set to rise to higher peaks 20 Company profile FERVER Federation proves that glass recycling is not a waste of time
Supplier profile Zippe24 A family affair
27 Lubricants Swabbing Robot lubricant success
28 History British Glass30 Small is beautiful
Case study Verallia Bad Wurzach32 Verallia installs synchronous reluctance technology
Refractories37 Recycling refractories40 Analysis of glass defect compositions from AZS refractory
Inspection44 Improving the quality of hollow glass through inspection
Plant technology46 A production monitoring solution
Front cover image wwwemede
Plus find us on Linked-In and Twitter
wwwglass-internationalcom
Glass_Int 32
20
24
13
CHINESE OVERVIEW
REFRACTORIES
SHANDONG HUAPENG - CHAIRMAN INTERVIEW
WWWGLASS-INTERNATIONALCOM
I N T E R N A T I O N A L
March 2016mdashVol39 No3
A GLOBAL REVIEW OF GLASSMAKING
Glass International M
arch 2016
Thin Glass
Tableware
Container Glass
Float Glass
Fibre Glass
Our fresh breeze for all types of glass production
Contents FEBindd 1 31616 941 AM
Editorrsquos comment
Glass International March 2016
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2
Itrsquos been an interesting month for me mostly spent in a car or train travelling to several meetings with prominent
suppliers and leading fi gures of the glass manufacturing industry
These people are at the forefront of our business and represent a variety of sub sectors They travel a lot speak to plenty of people and generally have their fi nger on the pulse of the industry
Among our varied chats ndash which are always a pleasure ndash one concern alone stood out the lack of young people enter-ing the industry
The glass industry is not an attractive one to youngsters Glass plants are hot noisy and dirty places Other industries with minimalistic air-conditioned offi c-es and a glamorous end product such as the automotive industry in the UK are regarded as cooler and cutting edge
One correspondent told me that the last innovation in the glass industry was 30 years ago with the introduction of the NNPD process Where will the new ideas come from if young talent is snapped up by other industries
It is not all hopeless Projects such as British Glassrsquo Glass Academy have raised the profi le of glass in schools and encour-aged apprentices to pursue a career in the industry Other national associations should follow its lead
Glass is still regarded as a desirable industry in developing nations such as
China India and the Philippines Young less weathered faces were prominent at events such as Glasspex in India the AFGM event in the Philippines and Glass-man in Mexico
The exchange of knowledge and new ideas is as important as ever If young peo-ple are opting to forge careers elsewhere glass must make use of the talent it has if it is to retain its leading position
The forthcoming Glassman Middle East conference is one such event where suppliers and manufacturers will present the latest trends and innovations
The Middle East with its fl ourishing youthful population is an ideal market in terms of attracting young people to glass It should follow the lead of the regionrsquos aluminium industry which has plenty of fresh-faced graduates working in it
Given the recent boom in activity in the MENA region including the lifting of trade sanctions in Iran the free to attend conference has attracted attention from manufacturers keen to visit the hollow glass industryrsquos most prominent suppli-ers The event will welcome the Director of Iranrsquos Noritazeh and the Operations Director of Frigoglassrsquos glass manufactur-ing division as keynote speakers
Greg MorrisEditorgregmorrisquartzltdcom
Greg Morris
Where have all the young people gone
wwwglass-internationalcom
Quartz Glass Portfolio
Editor Greg MorrisTel +44 (0)1737 855132Email gregmorrisquartzltdcom
Assistant Editor Sally LoveTel +44 (0)1737 855154Email sallylovequartzltdcom
Designer Annie BakerTel +44 (0)1737 855130Email anniebakerquartzltdcom
Sales Director Ken ClarkTel +44 (0)1737 855117Email kenclarkquartzltdcom
Sales Manager Jeremy FordreyTel +44 (0)1737 855133Email jeremyfordreyquartzltdcom
Production Executive Martin LawrenceManaging Director Steve Diprose
Chief Executive Offi cer Paul Michael
Subscriptions Elizabeth BarfordTel +44 (0)1737 855028 Fax +44 (0)1737 855034Email subscriptionsquartzltdcom
Published by Quartz Business Media LtdQuartz House 20 Clarendon Road Redhill Surrey RH1 1QX UKTel +44 (0)1737 855000 Fax +44 (0)1737 855034 Email glassquartzltdcomWebsite wwwglass-internationalcom
Glass International (ISSN 0143-7838) (USPS No 020-753) is published 10 times per year by Quartz Business Media Ltd and distributed in the US by DSW 75 Aberdeen Road Emigsville PA 17318-0437 Periodicals postage paid at Emigsville PA POSTMASTER send address changes to Glass International co PO Box 437 Emigsville PA 17318-0437
Offi cial publication of Abividro - the Brazilian Technical Association of Automatic Glass
Industries
Member of British Glass Manufacturersrsquo Confederation
China National Association for Glass Industry
United National Council of the glass industry (Steklosouz)
Glass International annual subscription rates including Glass International DirectoryFor one year UK pound164 all other countries pound231For two years UK pound295 all other countries pound416Airmail prices on request Single copies pound45
Glass International Directory 2015 editionUK pound206 all other countries pound217
Printed in UK byPensord Tram Road Pontlanfraith BlackwoodGwent NP12 2YA UK
copy Quartz Business Media Ltd 2015ISSN 0143-7838
Monthly journal for the industry worldwide
Directory 2015Annual international reference source
Glassman specialist exhibitions rotate between America Asia and Europe
wwwglass-internationalcom
China National Association for Glass Industry
Comment marchindd 1 31116 1235 PM
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International News
Glass International March 2016
5
Technology suppliers sign up for Middle East hollow glass event
NEWS IN BRIEF
Vitro sales boosted 22Growth in its container and flat glass businesses helped Vitro grow sales by 22
The Mexican company reported that the growth in the construction and automotive sectors as well as strong export and domestic sales had boosted business in the final quarter of 2015
Consolidated net sales increased 222 to US$229 million in the quarter it reported in its quarter four 2015 financials
Vitro CEO Mr Adrian Sada Cueva said ldquoThe strong dynamics of the construction market driven by shortages in Mexico and the economic recovery in the US coupled with the acquisition of new customers and increased exports of glass for the automotive sector and strong sales volumes in the pharmaceutical industry were the main factors that boosted sales this quarterrdquo
Frigoglass terminates GZI sale Frigoglass has terminated its agreement to sell its glass business in Dubai and Nigeria to GZ Industries (GZI)
The agreement was signed with GZI in May 2015 but a condition of the terms was not met GZI did not secure the necessary level of debt financing for the acquisition as a result of a change in regulations that restricts the ability to leverage Beta Glass and the adverse economic conditions in Nigeria
Amended offers were made by GZI but these were declined by Frigoglassrsquo Board of Directors
PPG sells PGW stakePPG is to sell 40 of its stake in Pittsburgh Glass Works (PGW)
The sale is in connection with LKQ Corporationrsquos plan to buy PGW which is expected to be completed by the end of the second quarter this year
PPG has held a minority interest in PGW since 2008 when it completed the sale of its automotive glass and services business to PGW
Several of the hollow glass in-dustryrsquos leading technology suppliers have confirmed their presence at the Glassman Mid-dle East event
German company Penneka-mp and UK group Electroglass have each taken a booth at the exhibition
They will be joined by French inspection group Tia-ma and Anderman Ceramics who will both present papers at the parallel conference
Pennekamp manufactures equipment for thermal pro-cesses (lehrs) as well as other
product areas within the glass industry
Electroglass has been in-volved in electric glass melt-ing technology since 1976 Its core activities are the develop-ment design engineering and supply of electric glass melting and conditioning systems and related equipment
Tiama is a provider of in-spection solutions for the hollow glass industry and will provide an update about its vi-sion product range
Anderman Ceramicsrsquo Gary Hateley will present a paper
titled Supplying refractory in-sulation for furnace linings
Glassman Middle East is a free to attend exhibition and conference dedicated to the hollowcontainertablewarespeciality glass sectors
It takes place on May 10 and 11 in Abu Dhabi UAE and vis-itors will include glass man-ufacturers from the region associations and technology suppliers
For more information visit wwwglassmaneventscommid-east
Iranian manufacturer Noritazeh confirmed as keynote speakerIranian tableware manufac-turer Noritazeh has been con-firmed as a keynote speaker at the Glassman Middle East hol-low glass conference
Noritazehrsquos Director Saeed
Kalafchi will give a 20-min-ute overview of the Iranian glass industry and provide an update on Noritazeh and its recent developments
Other speakers at the hol-
low glass conference include glass container manufacturer Frigoglass inspection compa-ny Tiama Pneumofore IRF Europa and French refracto-ries group Sefpro
Interglass and Pennekamp form LATAM partnership
Mexican group Interglass has formed a partnership with German lehrs company Pen-nekamp
The new partnership will see Interglass introduce and push Pennekamprsquos range of prod-ucts and equipment through-out the entire LATAM region
Jose Luis Velez Interglass Managing Director said ldquoWersquore very optimistic about
the success that this collabora-tion will bring to both compa-nies as Pennekamprsquos top tech-nology perfectly complements our solutions portfolio
ldquoWe are sure that this new partnership will be very pros-perous and that it will main-tain us on the right track to lead the LATAM market on be-half of all the companies that we represent and work withrdquo
March newsindd 1 31116 210 PM
International News
Glass International March 2016
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NEWS IN BRIEF
Borosilicate glassrsquo 125th anniversaryExactly 125 years ago Otto Schott the founder of the technology group Schott discovered borosilicate glass and created the basis for high-tech applications in the 21st century
The glass is used in a variety of applications from streaming of sports events to high-tech material research These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors
Thai Glass forms partnership with XparThai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry
The partnership is the crown on the co-operation which started two years ago between TGI which is the container glass manufacturing subsidiary of Berli Jucker in Thailand and Xpar Vision based in The Netherlands
The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera The trial was executed at the TGI production facility at Saraburi With the IR-D camera system all bottles are inspected in real time to detect critical defects
Libbey reports 35 drop in sales in 2015US tableware manufacturer Libbey reported a full year sales drop of 35 in 2015 compared to the prior year
In its full year financials for 2015 it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada
It said sales performance in the US and Canada last year was led by a 75 increase in sales within the segmentrsquos foodservice channel
For 2016 Libbey forecast a sales growth of 1 from $8223 million to $830 million
Ground clearing begins at Ethiopian bottling plantAtlasrsquo 100 owned subsid-iary East Africa Packaging Holdings (lsquoEAPHrsquo) is building a glass bottle manufacturing facility 45km north of Ethio-piarsquos capital Addis Ababa
The plant will have the ca-pacity to produce 105 million 330ml bottles a year
Named the lsquoChancho Pro-jectrsquo Atlas has commenced ground clearing at the site and held a ceremony to com-memorate the event (pictured with Atlasrsquo CEO Carl Esprey pictured second from left)
Commissioning of the fa-cility has been scheduled for 2018 with full production tar-geted for early 2019
Levelling of the 55 acre site has begun and the topsoil has been stripped
The Chancho Project site is located in an established in-dustrial area that is serviced by excellent road infrastruc-ture as well as power
Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropri-ate grades of silica sand and
limestone are available in de-posits 30km away from the site
An initial pre-feasibility study was completed at the Chancho Project and re-turned positive results
A full feasibility study is now being conducted in tandem with local and internation-al engineering consultants which is close to completion
The total capital expend-iture is estimated at US$42 million to be funded on a staged basis by a mixture of debt from local development banks other debt providers
industrial partners and equityFor the last five years due to
increased consumer demand and a young demographic Ethiopia has been attracting investment from internation-al beverage companies with more than $500 million in-vested to date
Beer production has been growing at a CAGR of 143 over the last 14 years with an additional 47 capacity cur-rently under construction
The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports
Record year for UK electric melting specialistUK-based electric melting spe-cialist Electroglass has report-ed a ten-year record in its 2015 results
ldquoDespite uncertainty and slow-down in a number of world markets we have had an excellent yearrdquo said Managing Director Richard Stormont
ldquoAll-electric furnace and forehearths projects for fluo-ride opal tableware glass in south Asia in particular have been significant contributors
to this along with borosili-cate electric forehearths work in the USA gas-to-electric soda-lime forehearth conver-sions in South Korea electric boosting projects in Indonesia and elsewhere and contin-uing development and sales of our Precision Control Bub-bling Systems
ldquoAlso holding up well are sales of hardware notably the Molycool and Vertical Splash-guard ranges of electrode
holders and our dry-type fore-hearth electrodesrdquo he added
ldquoThe rest of 2016 sees the commissioning of several re-cently supplied systems and work is expected to start on a number of significant new projects for the companyrdquo
Electroglass will be exhib-iting at the upcoming Glass-man Middle East show in Abu Dhabi on the 10th and 11th May
March newsindd 2 31116 210 PM
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
+ TECHNOLOGY OMCO uses tailored technology to weld and machine moulds plungers and neck rings
+ FLEXIBILITY OMCO uses efficient manufacturing processes enabling quick turnarounds for urgent jobs
+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
= QUALITY PROMPTLY DELIVERED AT A COMPETITIVE PRICE
MOULDSHOPS OMCO BELGIUM I OMCO AUSTRIA I OMCO UK I OMCO CROATIA I OMCO ISTANBUL I OMCO ROMANIA FOUNDRIES OMCO BELGIUM I OMCO SLOVENIA
OMCOLEADING MOULD MAKERTO THE GLASS WORLD
International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
Tomorrows Technology Today
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FIVES PRIUMreg TECHNOLOGY THE ULTIMATE ADDED VALUE TO YOUR INVESTMENT
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Glass International March 2016
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A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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28
Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
distributors are offered with guarantees covering temperature stability thermal homogeneity and
fuel consumption
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
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fi rst In practice however discontinued products
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competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
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hu
We build glass furnaces for you
Inspection
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Contents
Glass International March 2016
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1
March 2016 Vol39 No3
2 Editorrsquos Comment
5 International news
13 Company overview Shandong Huapeng A Chinese group with global plans
17 Chinese overview Chinarsquos container industry set to rise to higher peaks 20 Company profile FERVER Federation proves that glass recycling is not a waste of time
Supplier profile Zippe24 A family affair
27 Lubricants Swabbing Robot lubricant success
28 History British Glass30 Small is beautiful
Case study Verallia Bad Wurzach32 Verallia installs synchronous reluctance technology
Refractories37 Recycling refractories40 Analysis of glass defect compositions from AZS refractory
Inspection44 Improving the quality of hollow glass through inspection
Plant technology46 A production monitoring solution
Front cover image wwwemede
Plus find us on Linked-In and Twitter
wwwglass-internationalcom
Glass_Int 32
20
24
13
CHINESE OVERVIEW
REFRACTORIES
SHANDONG HUAPENG - CHAIRMAN INTERVIEW
WWWGLASS-INTERNATIONALCOM
I N T E R N A T I O N A L
March 2016mdashVol39 No3
A GLOBAL REVIEW OF GLASSMAKING
Glass International M
arch 2016
Thin Glass
Tableware
Container Glass
Float Glass
Fibre Glass
Our fresh breeze for all types of glass production
Contents FEBindd 1 31616 941 AM
Editorrsquos comment
Glass International March 2016
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2
Itrsquos been an interesting month for me mostly spent in a car or train travelling to several meetings with prominent
suppliers and leading fi gures of the glass manufacturing industry
These people are at the forefront of our business and represent a variety of sub sectors They travel a lot speak to plenty of people and generally have their fi nger on the pulse of the industry
Among our varied chats ndash which are always a pleasure ndash one concern alone stood out the lack of young people enter-ing the industry
The glass industry is not an attractive one to youngsters Glass plants are hot noisy and dirty places Other industries with minimalistic air-conditioned offi c-es and a glamorous end product such as the automotive industry in the UK are regarded as cooler and cutting edge
One correspondent told me that the last innovation in the glass industry was 30 years ago with the introduction of the NNPD process Where will the new ideas come from if young talent is snapped up by other industries
It is not all hopeless Projects such as British Glassrsquo Glass Academy have raised the profi le of glass in schools and encour-aged apprentices to pursue a career in the industry Other national associations should follow its lead
Glass is still regarded as a desirable industry in developing nations such as
China India and the Philippines Young less weathered faces were prominent at events such as Glasspex in India the AFGM event in the Philippines and Glass-man in Mexico
The exchange of knowledge and new ideas is as important as ever If young peo-ple are opting to forge careers elsewhere glass must make use of the talent it has if it is to retain its leading position
The forthcoming Glassman Middle East conference is one such event where suppliers and manufacturers will present the latest trends and innovations
The Middle East with its fl ourishing youthful population is an ideal market in terms of attracting young people to glass It should follow the lead of the regionrsquos aluminium industry which has plenty of fresh-faced graduates working in it
Given the recent boom in activity in the MENA region including the lifting of trade sanctions in Iran the free to attend conference has attracted attention from manufacturers keen to visit the hollow glass industryrsquos most prominent suppli-ers The event will welcome the Director of Iranrsquos Noritazeh and the Operations Director of Frigoglassrsquos glass manufactur-ing division as keynote speakers
Greg MorrisEditorgregmorrisquartzltdcom
Greg Morris
Where have all the young people gone
wwwglass-internationalcom
Quartz Glass Portfolio
Editor Greg MorrisTel +44 (0)1737 855132Email gregmorrisquartzltdcom
Assistant Editor Sally LoveTel +44 (0)1737 855154Email sallylovequartzltdcom
Designer Annie BakerTel +44 (0)1737 855130Email anniebakerquartzltdcom
Sales Director Ken ClarkTel +44 (0)1737 855117Email kenclarkquartzltdcom
Sales Manager Jeremy FordreyTel +44 (0)1737 855133Email jeremyfordreyquartzltdcom
Production Executive Martin LawrenceManaging Director Steve Diprose
Chief Executive Offi cer Paul Michael
Subscriptions Elizabeth BarfordTel +44 (0)1737 855028 Fax +44 (0)1737 855034Email subscriptionsquartzltdcom
Published by Quartz Business Media LtdQuartz House 20 Clarendon Road Redhill Surrey RH1 1QX UKTel +44 (0)1737 855000 Fax +44 (0)1737 855034 Email glassquartzltdcomWebsite wwwglass-internationalcom
Glass International (ISSN 0143-7838) (USPS No 020-753) is published 10 times per year by Quartz Business Media Ltd and distributed in the US by DSW 75 Aberdeen Road Emigsville PA 17318-0437 Periodicals postage paid at Emigsville PA POSTMASTER send address changes to Glass International co PO Box 437 Emigsville PA 17318-0437
Offi cial publication of Abividro - the Brazilian Technical Association of Automatic Glass
Industries
Member of British Glass Manufacturersrsquo Confederation
China National Association for Glass Industry
United National Council of the glass industry (Steklosouz)
Glass International annual subscription rates including Glass International DirectoryFor one year UK pound164 all other countries pound231For two years UK pound295 all other countries pound416Airmail prices on request Single copies pound45
Glass International Directory 2015 editionUK pound206 all other countries pound217
Printed in UK byPensord Tram Road Pontlanfraith BlackwoodGwent NP12 2YA UK
copy Quartz Business Media Ltd 2015ISSN 0143-7838
Monthly journal for the industry worldwide
Directory 2015Annual international reference source
Glassman specialist exhibitions rotate between America Asia and Europe
wwwglass-internationalcom
China National Association for Glass Industry
Comment marchindd 1 31116 1235 PM
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Bucher Emhart Glass The future of glassmaking technology delivered today
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IS machine AIS machine
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BEG_Portfolio-Glass_Intlindd 1 9315 305 PM
ENSURE THAT YOUR INVESTMENT PAYS OFFThat is why our furnaces and conditioning
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wwwsorgde
International News
Glass International March 2016
5
Technology suppliers sign up for Middle East hollow glass event
NEWS IN BRIEF
Vitro sales boosted 22Growth in its container and flat glass businesses helped Vitro grow sales by 22
The Mexican company reported that the growth in the construction and automotive sectors as well as strong export and domestic sales had boosted business in the final quarter of 2015
Consolidated net sales increased 222 to US$229 million in the quarter it reported in its quarter four 2015 financials
Vitro CEO Mr Adrian Sada Cueva said ldquoThe strong dynamics of the construction market driven by shortages in Mexico and the economic recovery in the US coupled with the acquisition of new customers and increased exports of glass for the automotive sector and strong sales volumes in the pharmaceutical industry were the main factors that boosted sales this quarterrdquo
Frigoglass terminates GZI sale Frigoglass has terminated its agreement to sell its glass business in Dubai and Nigeria to GZ Industries (GZI)
The agreement was signed with GZI in May 2015 but a condition of the terms was not met GZI did not secure the necessary level of debt financing for the acquisition as a result of a change in regulations that restricts the ability to leverage Beta Glass and the adverse economic conditions in Nigeria
Amended offers were made by GZI but these were declined by Frigoglassrsquo Board of Directors
PPG sells PGW stakePPG is to sell 40 of its stake in Pittsburgh Glass Works (PGW)
The sale is in connection with LKQ Corporationrsquos plan to buy PGW which is expected to be completed by the end of the second quarter this year
PPG has held a minority interest in PGW since 2008 when it completed the sale of its automotive glass and services business to PGW
Several of the hollow glass in-dustryrsquos leading technology suppliers have confirmed their presence at the Glassman Mid-dle East event
German company Penneka-mp and UK group Electroglass have each taken a booth at the exhibition
They will be joined by French inspection group Tia-ma and Anderman Ceramics who will both present papers at the parallel conference
Pennekamp manufactures equipment for thermal pro-cesses (lehrs) as well as other
product areas within the glass industry
Electroglass has been in-volved in electric glass melt-ing technology since 1976 Its core activities are the develop-ment design engineering and supply of electric glass melting and conditioning systems and related equipment
Tiama is a provider of in-spection solutions for the hollow glass industry and will provide an update about its vi-sion product range
Anderman Ceramicsrsquo Gary Hateley will present a paper
titled Supplying refractory in-sulation for furnace linings
Glassman Middle East is a free to attend exhibition and conference dedicated to the hollowcontainertablewarespeciality glass sectors
It takes place on May 10 and 11 in Abu Dhabi UAE and vis-itors will include glass man-ufacturers from the region associations and technology suppliers
For more information visit wwwglassmaneventscommid-east
Iranian manufacturer Noritazeh confirmed as keynote speakerIranian tableware manufac-turer Noritazeh has been con-firmed as a keynote speaker at the Glassman Middle East hol-low glass conference
Noritazehrsquos Director Saeed
Kalafchi will give a 20-min-ute overview of the Iranian glass industry and provide an update on Noritazeh and its recent developments
Other speakers at the hol-
low glass conference include glass container manufacturer Frigoglass inspection compa-ny Tiama Pneumofore IRF Europa and French refracto-ries group Sefpro
Interglass and Pennekamp form LATAM partnership
Mexican group Interglass has formed a partnership with German lehrs company Pen-nekamp
The new partnership will see Interglass introduce and push Pennekamprsquos range of prod-ucts and equipment through-out the entire LATAM region
Jose Luis Velez Interglass Managing Director said ldquoWersquore very optimistic about
the success that this collabora-tion will bring to both compa-nies as Pennekamprsquos top tech-nology perfectly complements our solutions portfolio
ldquoWe are sure that this new partnership will be very pros-perous and that it will main-tain us on the right track to lead the LATAM market on be-half of all the companies that we represent and work withrdquo
March newsindd 1 31116 210 PM
International News
Glass International March 2016
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NEWS IN BRIEF
Borosilicate glassrsquo 125th anniversaryExactly 125 years ago Otto Schott the founder of the technology group Schott discovered borosilicate glass and created the basis for high-tech applications in the 21st century
The glass is used in a variety of applications from streaming of sports events to high-tech material research These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors
Thai Glass forms partnership with XparThai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry
The partnership is the crown on the co-operation which started two years ago between TGI which is the container glass manufacturing subsidiary of Berli Jucker in Thailand and Xpar Vision based in The Netherlands
The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera The trial was executed at the TGI production facility at Saraburi With the IR-D camera system all bottles are inspected in real time to detect critical defects
Libbey reports 35 drop in sales in 2015US tableware manufacturer Libbey reported a full year sales drop of 35 in 2015 compared to the prior year
In its full year financials for 2015 it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada
It said sales performance in the US and Canada last year was led by a 75 increase in sales within the segmentrsquos foodservice channel
For 2016 Libbey forecast a sales growth of 1 from $8223 million to $830 million
Ground clearing begins at Ethiopian bottling plantAtlasrsquo 100 owned subsid-iary East Africa Packaging Holdings (lsquoEAPHrsquo) is building a glass bottle manufacturing facility 45km north of Ethio-piarsquos capital Addis Ababa
The plant will have the ca-pacity to produce 105 million 330ml bottles a year
Named the lsquoChancho Pro-jectrsquo Atlas has commenced ground clearing at the site and held a ceremony to com-memorate the event (pictured with Atlasrsquo CEO Carl Esprey pictured second from left)
Commissioning of the fa-cility has been scheduled for 2018 with full production tar-geted for early 2019
Levelling of the 55 acre site has begun and the topsoil has been stripped
The Chancho Project site is located in an established in-dustrial area that is serviced by excellent road infrastruc-ture as well as power
Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropri-ate grades of silica sand and
limestone are available in de-posits 30km away from the site
An initial pre-feasibility study was completed at the Chancho Project and re-turned positive results
A full feasibility study is now being conducted in tandem with local and internation-al engineering consultants which is close to completion
The total capital expend-iture is estimated at US$42 million to be funded on a staged basis by a mixture of debt from local development banks other debt providers
industrial partners and equityFor the last five years due to
increased consumer demand and a young demographic Ethiopia has been attracting investment from internation-al beverage companies with more than $500 million in-vested to date
Beer production has been growing at a CAGR of 143 over the last 14 years with an additional 47 capacity cur-rently under construction
The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports
Record year for UK electric melting specialistUK-based electric melting spe-cialist Electroglass has report-ed a ten-year record in its 2015 results
ldquoDespite uncertainty and slow-down in a number of world markets we have had an excellent yearrdquo said Managing Director Richard Stormont
ldquoAll-electric furnace and forehearths projects for fluo-ride opal tableware glass in south Asia in particular have been significant contributors
to this along with borosili-cate electric forehearths work in the USA gas-to-electric soda-lime forehearth conver-sions in South Korea electric boosting projects in Indonesia and elsewhere and contin-uing development and sales of our Precision Control Bub-bling Systems
ldquoAlso holding up well are sales of hardware notably the Molycool and Vertical Splash-guard ranges of electrode
holders and our dry-type fore-hearth electrodesrdquo he added
ldquoThe rest of 2016 sees the commissioning of several re-cently supplied systems and work is expected to start on a number of significant new projects for the companyrdquo
Electroglass will be exhib-iting at the upcoming Glass-man Middle East show in Abu Dhabi on the 10th and 11th May
March newsindd 2 31116 210 PM
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
+ TECHNOLOGY OMCO uses tailored technology to weld and machine moulds plungers and neck rings
+ FLEXIBILITY OMCO uses efficient manufacturing processes enabling quick turnarounds for urgent jobs
+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
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OMCOLEADING MOULD MAKERTO THE GLASS WORLD
International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
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Thin Glass
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We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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nati
onal
com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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28
Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
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2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Editorrsquos comment
Glass International March 2016
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Itrsquos been an interesting month for me mostly spent in a car or train travelling to several meetings with prominent
suppliers and leading fi gures of the glass manufacturing industry
These people are at the forefront of our business and represent a variety of sub sectors They travel a lot speak to plenty of people and generally have their fi nger on the pulse of the industry
Among our varied chats ndash which are always a pleasure ndash one concern alone stood out the lack of young people enter-ing the industry
The glass industry is not an attractive one to youngsters Glass plants are hot noisy and dirty places Other industries with minimalistic air-conditioned offi c-es and a glamorous end product such as the automotive industry in the UK are regarded as cooler and cutting edge
One correspondent told me that the last innovation in the glass industry was 30 years ago with the introduction of the NNPD process Where will the new ideas come from if young talent is snapped up by other industries
It is not all hopeless Projects such as British Glassrsquo Glass Academy have raised the profi le of glass in schools and encour-aged apprentices to pursue a career in the industry Other national associations should follow its lead
Glass is still regarded as a desirable industry in developing nations such as
China India and the Philippines Young less weathered faces were prominent at events such as Glasspex in India the AFGM event in the Philippines and Glass-man in Mexico
The exchange of knowledge and new ideas is as important as ever If young peo-ple are opting to forge careers elsewhere glass must make use of the talent it has if it is to retain its leading position
The forthcoming Glassman Middle East conference is one such event where suppliers and manufacturers will present the latest trends and innovations
The Middle East with its fl ourishing youthful population is an ideal market in terms of attracting young people to glass It should follow the lead of the regionrsquos aluminium industry which has plenty of fresh-faced graduates working in it
Given the recent boom in activity in the MENA region including the lifting of trade sanctions in Iran the free to attend conference has attracted attention from manufacturers keen to visit the hollow glass industryrsquos most prominent suppli-ers The event will welcome the Director of Iranrsquos Noritazeh and the Operations Director of Frigoglassrsquos glass manufactur-ing division as keynote speakers
Greg MorrisEditorgregmorrisquartzltdcom
Greg Morris
Where have all the young people gone
wwwglass-internationalcom
Quartz Glass Portfolio
Editor Greg MorrisTel +44 (0)1737 855132Email gregmorrisquartzltdcom
Assistant Editor Sally LoveTel +44 (0)1737 855154Email sallylovequartzltdcom
Designer Annie BakerTel +44 (0)1737 855130Email anniebakerquartzltdcom
Sales Director Ken ClarkTel +44 (0)1737 855117Email kenclarkquartzltdcom
Sales Manager Jeremy FordreyTel +44 (0)1737 855133Email jeremyfordreyquartzltdcom
Production Executive Martin LawrenceManaging Director Steve Diprose
Chief Executive Offi cer Paul Michael
Subscriptions Elizabeth BarfordTel +44 (0)1737 855028 Fax +44 (0)1737 855034Email subscriptionsquartzltdcom
Published by Quartz Business Media LtdQuartz House 20 Clarendon Road Redhill Surrey RH1 1QX UKTel +44 (0)1737 855000 Fax +44 (0)1737 855034 Email glassquartzltdcomWebsite wwwglass-internationalcom
Glass International (ISSN 0143-7838) (USPS No 020-753) is published 10 times per year by Quartz Business Media Ltd and distributed in the US by DSW 75 Aberdeen Road Emigsville PA 17318-0437 Periodicals postage paid at Emigsville PA POSTMASTER send address changes to Glass International co PO Box 437 Emigsville PA 17318-0437
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Industries
Member of British Glass Manufacturersrsquo Confederation
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Glass International annual subscription rates including Glass International DirectoryFor one year UK pound164 all other countries pound231For two years UK pound295 all other countries pound416Airmail prices on request Single copies pound45
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China National Association for Glass Industry
Comment marchindd 1 31116 1235 PM
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International News
Glass International March 2016
5
Technology suppliers sign up for Middle East hollow glass event
NEWS IN BRIEF
Vitro sales boosted 22Growth in its container and flat glass businesses helped Vitro grow sales by 22
The Mexican company reported that the growth in the construction and automotive sectors as well as strong export and domestic sales had boosted business in the final quarter of 2015
Consolidated net sales increased 222 to US$229 million in the quarter it reported in its quarter four 2015 financials
Vitro CEO Mr Adrian Sada Cueva said ldquoThe strong dynamics of the construction market driven by shortages in Mexico and the economic recovery in the US coupled with the acquisition of new customers and increased exports of glass for the automotive sector and strong sales volumes in the pharmaceutical industry were the main factors that boosted sales this quarterrdquo
Frigoglass terminates GZI sale Frigoglass has terminated its agreement to sell its glass business in Dubai and Nigeria to GZ Industries (GZI)
The agreement was signed with GZI in May 2015 but a condition of the terms was not met GZI did not secure the necessary level of debt financing for the acquisition as a result of a change in regulations that restricts the ability to leverage Beta Glass and the adverse economic conditions in Nigeria
Amended offers were made by GZI but these were declined by Frigoglassrsquo Board of Directors
PPG sells PGW stakePPG is to sell 40 of its stake in Pittsburgh Glass Works (PGW)
The sale is in connection with LKQ Corporationrsquos plan to buy PGW which is expected to be completed by the end of the second quarter this year
PPG has held a minority interest in PGW since 2008 when it completed the sale of its automotive glass and services business to PGW
Several of the hollow glass in-dustryrsquos leading technology suppliers have confirmed their presence at the Glassman Mid-dle East event
German company Penneka-mp and UK group Electroglass have each taken a booth at the exhibition
They will be joined by French inspection group Tia-ma and Anderman Ceramics who will both present papers at the parallel conference
Pennekamp manufactures equipment for thermal pro-cesses (lehrs) as well as other
product areas within the glass industry
Electroglass has been in-volved in electric glass melt-ing technology since 1976 Its core activities are the develop-ment design engineering and supply of electric glass melting and conditioning systems and related equipment
Tiama is a provider of in-spection solutions for the hollow glass industry and will provide an update about its vi-sion product range
Anderman Ceramicsrsquo Gary Hateley will present a paper
titled Supplying refractory in-sulation for furnace linings
Glassman Middle East is a free to attend exhibition and conference dedicated to the hollowcontainertablewarespeciality glass sectors
It takes place on May 10 and 11 in Abu Dhabi UAE and vis-itors will include glass man-ufacturers from the region associations and technology suppliers
For more information visit wwwglassmaneventscommid-east
Iranian manufacturer Noritazeh confirmed as keynote speakerIranian tableware manufac-turer Noritazeh has been con-firmed as a keynote speaker at the Glassman Middle East hol-low glass conference
Noritazehrsquos Director Saeed
Kalafchi will give a 20-min-ute overview of the Iranian glass industry and provide an update on Noritazeh and its recent developments
Other speakers at the hol-
low glass conference include glass container manufacturer Frigoglass inspection compa-ny Tiama Pneumofore IRF Europa and French refracto-ries group Sefpro
Interglass and Pennekamp form LATAM partnership
Mexican group Interglass has formed a partnership with German lehrs company Pen-nekamp
The new partnership will see Interglass introduce and push Pennekamprsquos range of prod-ucts and equipment through-out the entire LATAM region
Jose Luis Velez Interglass Managing Director said ldquoWersquore very optimistic about
the success that this collabora-tion will bring to both compa-nies as Pennekamprsquos top tech-nology perfectly complements our solutions portfolio
ldquoWe are sure that this new partnership will be very pros-perous and that it will main-tain us on the right track to lead the LATAM market on be-half of all the companies that we represent and work withrdquo
March newsindd 1 31116 210 PM
International News
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NEWS IN BRIEF
Borosilicate glassrsquo 125th anniversaryExactly 125 years ago Otto Schott the founder of the technology group Schott discovered borosilicate glass and created the basis for high-tech applications in the 21st century
The glass is used in a variety of applications from streaming of sports events to high-tech material research These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors
Thai Glass forms partnership with XparThai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry
The partnership is the crown on the co-operation which started two years ago between TGI which is the container glass manufacturing subsidiary of Berli Jucker in Thailand and Xpar Vision based in The Netherlands
The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera The trial was executed at the TGI production facility at Saraburi With the IR-D camera system all bottles are inspected in real time to detect critical defects
Libbey reports 35 drop in sales in 2015US tableware manufacturer Libbey reported a full year sales drop of 35 in 2015 compared to the prior year
In its full year financials for 2015 it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada
It said sales performance in the US and Canada last year was led by a 75 increase in sales within the segmentrsquos foodservice channel
For 2016 Libbey forecast a sales growth of 1 from $8223 million to $830 million
Ground clearing begins at Ethiopian bottling plantAtlasrsquo 100 owned subsid-iary East Africa Packaging Holdings (lsquoEAPHrsquo) is building a glass bottle manufacturing facility 45km north of Ethio-piarsquos capital Addis Ababa
The plant will have the ca-pacity to produce 105 million 330ml bottles a year
Named the lsquoChancho Pro-jectrsquo Atlas has commenced ground clearing at the site and held a ceremony to com-memorate the event (pictured with Atlasrsquo CEO Carl Esprey pictured second from left)
Commissioning of the fa-cility has been scheduled for 2018 with full production tar-geted for early 2019
Levelling of the 55 acre site has begun and the topsoil has been stripped
The Chancho Project site is located in an established in-dustrial area that is serviced by excellent road infrastruc-ture as well as power
Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropri-ate grades of silica sand and
limestone are available in de-posits 30km away from the site
An initial pre-feasibility study was completed at the Chancho Project and re-turned positive results
A full feasibility study is now being conducted in tandem with local and internation-al engineering consultants which is close to completion
The total capital expend-iture is estimated at US$42 million to be funded on a staged basis by a mixture of debt from local development banks other debt providers
industrial partners and equityFor the last five years due to
increased consumer demand and a young demographic Ethiopia has been attracting investment from internation-al beverage companies with more than $500 million in-vested to date
Beer production has been growing at a CAGR of 143 over the last 14 years with an additional 47 capacity cur-rently under construction
The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports
Record year for UK electric melting specialistUK-based electric melting spe-cialist Electroglass has report-ed a ten-year record in its 2015 results
ldquoDespite uncertainty and slow-down in a number of world markets we have had an excellent yearrdquo said Managing Director Richard Stormont
ldquoAll-electric furnace and forehearths projects for fluo-ride opal tableware glass in south Asia in particular have been significant contributors
to this along with borosili-cate electric forehearths work in the USA gas-to-electric soda-lime forehearth conver-sions in South Korea electric boosting projects in Indonesia and elsewhere and contin-uing development and sales of our Precision Control Bub-bling Systems
ldquoAlso holding up well are sales of hardware notably the Molycool and Vertical Splash-guard ranges of electrode
holders and our dry-type fore-hearth electrodesrdquo he added
ldquoThe rest of 2016 sees the commissioning of several re-cently supplied systems and work is expected to start on a number of significant new projects for the companyrdquo
Electroglass will be exhib-iting at the upcoming Glass-man Middle East show in Abu Dhabi on the 10th and 11th May
March newsindd 2 31116 210 PM
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
+ TECHNOLOGY OMCO uses tailored technology to weld and machine moulds plungers and neck rings
+ FLEXIBILITY OMCO uses efficient manufacturing processes enabling quick turnarounds for urgent jobs
+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
= QUALITY PROMPTLY DELIVERED AT A COMPETITIVE PRICE
MOULDSHOPS OMCO BELGIUM I OMCO AUSTRIA I OMCO UK I OMCO CROATIA I OMCO ISTANBUL I OMCO ROMANIA FOUNDRIES OMCO BELGIUM I OMCO SLOVENIA
OMCOLEADING MOULD MAKERTO THE GLASS WORLD
International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
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G L A S S Q U A L I T YFives is a leading provider of glass technologies for the most demanding applications ultra-thin automotive pharmaceutical fiber solar crystal and speciality glass We contractually guarantee the productivity and environmental performance of your plant for secured profitability of your investmentWith over 60 years of experience in the glass industry Fives designs engineers manufactures installs tests and commissions glass equipment in a wide range of glass processes and applications all over the worldTrust Fives professionals to enhance your plantrsquos performance and competitiveness and to optimize your investmentglassfivesgroupcom wwwfivesgroupcom
FIVES PRIUMreg TECHNOLOGY THE ULTIMATE ADDED VALUE TO YOUR INVESTMENT
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
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Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
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2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Messages Notes
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Laboratory Mould
Vertech 15indd 2 31016 952 AM
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Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812Email salesmontselascouk wwwmontselascouk
MANUFACTURERS AND SUPPLIERS OF SELAS SQUARE PORT GAS amp AIR VALVES
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Bucher Emhart Glass The future of glassmaking technology delivered today
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ENSURE THAT YOUR INVESTMENT PAYS OFFThat is why our furnaces and conditioning
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International News
Glass International March 2016
5
Technology suppliers sign up for Middle East hollow glass event
NEWS IN BRIEF
Vitro sales boosted 22Growth in its container and flat glass businesses helped Vitro grow sales by 22
The Mexican company reported that the growth in the construction and automotive sectors as well as strong export and domestic sales had boosted business in the final quarter of 2015
Consolidated net sales increased 222 to US$229 million in the quarter it reported in its quarter four 2015 financials
Vitro CEO Mr Adrian Sada Cueva said ldquoThe strong dynamics of the construction market driven by shortages in Mexico and the economic recovery in the US coupled with the acquisition of new customers and increased exports of glass for the automotive sector and strong sales volumes in the pharmaceutical industry were the main factors that boosted sales this quarterrdquo
Frigoglass terminates GZI sale Frigoglass has terminated its agreement to sell its glass business in Dubai and Nigeria to GZ Industries (GZI)
The agreement was signed with GZI in May 2015 but a condition of the terms was not met GZI did not secure the necessary level of debt financing for the acquisition as a result of a change in regulations that restricts the ability to leverage Beta Glass and the adverse economic conditions in Nigeria
Amended offers were made by GZI but these were declined by Frigoglassrsquo Board of Directors
PPG sells PGW stakePPG is to sell 40 of its stake in Pittsburgh Glass Works (PGW)
The sale is in connection with LKQ Corporationrsquos plan to buy PGW which is expected to be completed by the end of the second quarter this year
PPG has held a minority interest in PGW since 2008 when it completed the sale of its automotive glass and services business to PGW
Several of the hollow glass in-dustryrsquos leading technology suppliers have confirmed their presence at the Glassman Mid-dle East event
German company Penneka-mp and UK group Electroglass have each taken a booth at the exhibition
They will be joined by French inspection group Tia-ma and Anderman Ceramics who will both present papers at the parallel conference
Pennekamp manufactures equipment for thermal pro-cesses (lehrs) as well as other
product areas within the glass industry
Electroglass has been in-volved in electric glass melt-ing technology since 1976 Its core activities are the develop-ment design engineering and supply of electric glass melting and conditioning systems and related equipment
Tiama is a provider of in-spection solutions for the hollow glass industry and will provide an update about its vi-sion product range
Anderman Ceramicsrsquo Gary Hateley will present a paper
titled Supplying refractory in-sulation for furnace linings
Glassman Middle East is a free to attend exhibition and conference dedicated to the hollowcontainertablewarespeciality glass sectors
It takes place on May 10 and 11 in Abu Dhabi UAE and vis-itors will include glass man-ufacturers from the region associations and technology suppliers
For more information visit wwwglassmaneventscommid-east
Iranian manufacturer Noritazeh confirmed as keynote speakerIranian tableware manufac-turer Noritazeh has been con-firmed as a keynote speaker at the Glassman Middle East hol-low glass conference
Noritazehrsquos Director Saeed
Kalafchi will give a 20-min-ute overview of the Iranian glass industry and provide an update on Noritazeh and its recent developments
Other speakers at the hol-
low glass conference include glass container manufacturer Frigoglass inspection compa-ny Tiama Pneumofore IRF Europa and French refracto-ries group Sefpro
Interglass and Pennekamp form LATAM partnership
Mexican group Interglass has formed a partnership with German lehrs company Pen-nekamp
The new partnership will see Interglass introduce and push Pennekamprsquos range of prod-ucts and equipment through-out the entire LATAM region
Jose Luis Velez Interglass Managing Director said ldquoWersquore very optimistic about
the success that this collabora-tion will bring to both compa-nies as Pennekamprsquos top tech-nology perfectly complements our solutions portfolio
ldquoWe are sure that this new partnership will be very pros-perous and that it will main-tain us on the right track to lead the LATAM market on be-half of all the companies that we represent and work withrdquo
March newsindd 1 31116 210 PM
International News
Glass International March 2016
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NEWS IN BRIEF
Borosilicate glassrsquo 125th anniversaryExactly 125 years ago Otto Schott the founder of the technology group Schott discovered borosilicate glass and created the basis for high-tech applications in the 21st century
The glass is used in a variety of applications from streaming of sports events to high-tech material research These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors
Thai Glass forms partnership with XparThai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry
The partnership is the crown on the co-operation which started two years ago between TGI which is the container glass manufacturing subsidiary of Berli Jucker in Thailand and Xpar Vision based in The Netherlands
The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera The trial was executed at the TGI production facility at Saraburi With the IR-D camera system all bottles are inspected in real time to detect critical defects
Libbey reports 35 drop in sales in 2015US tableware manufacturer Libbey reported a full year sales drop of 35 in 2015 compared to the prior year
In its full year financials for 2015 it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada
It said sales performance in the US and Canada last year was led by a 75 increase in sales within the segmentrsquos foodservice channel
For 2016 Libbey forecast a sales growth of 1 from $8223 million to $830 million
Ground clearing begins at Ethiopian bottling plantAtlasrsquo 100 owned subsid-iary East Africa Packaging Holdings (lsquoEAPHrsquo) is building a glass bottle manufacturing facility 45km north of Ethio-piarsquos capital Addis Ababa
The plant will have the ca-pacity to produce 105 million 330ml bottles a year
Named the lsquoChancho Pro-jectrsquo Atlas has commenced ground clearing at the site and held a ceremony to com-memorate the event (pictured with Atlasrsquo CEO Carl Esprey pictured second from left)
Commissioning of the fa-cility has been scheduled for 2018 with full production tar-geted for early 2019
Levelling of the 55 acre site has begun and the topsoil has been stripped
The Chancho Project site is located in an established in-dustrial area that is serviced by excellent road infrastruc-ture as well as power
Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropri-ate grades of silica sand and
limestone are available in de-posits 30km away from the site
An initial pre-feasibility study was completed at the Chancho Project and re-turned positive results
A full feasibility study is now being conducted in tandem with local and internation-al engineering consultants which is close to completion
The total capital expend-iture is estimated at US$42 million to be funded on a staged basis by a mixture of debt from local development banks other debt providers
industrial partners and equityFor the last five years due to
increased consumer demand and a young demographic Ethiopia has been attracting investment from internation-al beverage companies with more than $500 million in-vested to date
Beer production has been growing at a CAGR of 143 over the last 14 years with an additional 47 capacity cur-rently under construction
The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports
Record year for UK electric melting specialistUK-based electric melting spe-cialist Electroglass has report-ed a ten-year record in its 2015 results
ldquoDespite uncertainty and slow-down in a number of world markets we have had an excellent yearrdquo said Managing Director Richard Stormont
ldquoAll-electric furnace and forehearths projects for fluo-ride opal tableware glass in south Asia in particular have been significant contributors
to this along with borosili-cate electric forehearths work in the USA gas-to-electric soda-lime forehearth conver-sions in South Korea electric boosting projects in Indonesia and elsewhere and contin-uing development and sales of our Precision Control Bub-bling Systems
ldquoAlso holding up well are sales of hardware notably the Molycool and Vertical Splash-guard ranges of electrode
holders and our dry-type fore-hearth electrodesrdquo he added
ldquoThe rest of 2016 sees the commissioning of several re-cently supplied systems and work is expected to start on a number of significant new projects for the companyrdquo
Electroglass will be exhib-iting at the upcoming Glass-man Middle East show in Abu Dhabi on the 10th and 11th May
March newsindd 2 31116 210 PM
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
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+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
= QUALITY PROMPTLY DELIVERED AT A COMPETITIVE PRICE
MOULDSHOPS OMCO BELGIUM I OMCO AUSTRIA I OMCO UK I OMCO CROATIA I OMCO ISTANBUL I OMCO ROMANIA FOUNDRIES OMCO BELGIUM I OMCO SLOVENIA
OMCOLEADING MOULD MAKERTO THE GLASS WORLD
International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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10
NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
Tomorrows Technology Today
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FIC - Cube ad 2016 20216 1200 Page 1
G L A S S Q U A L I T YFives is a leading provider of glass technologies for the most demanding applications ultra-thin automotive pharmaceutical fiber solar crystal and speciality glass We contractually guarantee the productivity and environmental performance of your plant for secured profitability of your investmentWith over 60 years of experience in the glass industry Fives designs engineers manufactures installs tests and commissions glass equipment in a wide range of glass processes and applications all over the worldTrust Fives professionals to enhance your plantrsquos performance and competitiveness and to optimize your investmentglassfivesgroupcom wwwfivesgroupcom
FIVES PRIUMreg TECHNOLOGY THE ULTIMATE ADDED VALUE TO YOUR INVESTMENT
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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-int
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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-int
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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wg
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-int
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alc
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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wg
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-int
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shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
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Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
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An IS machine keeps going almost indefi nitely ndash
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
available today
PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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International News
Glass International March 2016
5
Technology suppliers sign up for Middle East hollow glass event
NEWS IN BRIEF
Vitro sales boosted 22Growth in its container and flat glass businesses helped Vitro grow sales by 22
The Mexican company reported that the growth in the construction and automotive sectors as well as strong export and domestic sales had boosted business in the final quarter of 2015
Consolidated net sales increased 222 to US$229 million in the quarter it reported in its quarter four 2015 financials
Vitro CEO Mr Adrian Sada Cueva said ldquoThe strong dynamics of the construction market driven by shortages in Mexico and the economic recovery in the US coupled with the acquisition of new customers and increased exports of glass for the automotive sector and strong sales volumes in the pharmaceutical industry were the main factors that boosted sales this quarterrdquo
Frigoglass terminates GZI sale Frigoglass has terminated its agreement to sell its glass business in Dubai and Nigeria to GZ Industries (GZI)
The agreement was signed with GZI in May 2015 but a condition of the terms was not met GZI did not secure the necessary level of debt financing for the acquisition as a result of a change in regulations that restricts the ability to leverage Beta Glass and the adverse economic conditions in Nigeria
Amended offers were made by GZI but these were declined by Frigoglassrsquo Board of Directors
PPG sells PGW stakePPG is to sell 40 of its stake in Pittsburgh Glass Works (PGW)
The sale is in connection with LKQ Corporationrsquos plan to buy PGW which is expected to be completed by the end of the second quarter this year
PPG has held a minority interest in PGW since 2008 when it completed the sale of its automotive glass and services business to PGW
Several of the hollow glass in-dustryrsquos leading technology suppliers have confirmed their presence at the Glassman Mid-dle East event
German company Penneka-mp and UK group Electroglass have each taken a booth at the exhibition
They will be joined by French inspection group Tia-ma and Anderman Ceramics who will both present papers at the parallel conference
Pennekamp manufactures equipment for thermal pro-cesses (lehrs) as well as other
product areas within the glass industry
Electroglass has been in-volved in electric glass melt-ing technology since 1976 Its core activities are the develop-ment design engineering and supply of electric glass melting and conditioning systems and related equipment
Tiama is a provider of in-spection solutions for the hollow glass industry and will provide an update about its vi-sion product range
Anderman Ceramicsrsquo Gary Hateley will present a paper
titled Supplying refractory in-sulation for furnace linings
Glassman Middle East is a free to attend exhibition and conference dedicated to the hollowcontainertablewarespeciality glass sectors
It takes place on May 10 and 11 in Abu Dhabi UAE and vis-itors will include glass man-ufacturers from the region associations and technology suppliers
For more information visit wwwglassmaneventscommid-east
Iranian manufacturer Noritazeh confirmed as keynote speakerIranian tableware manufac-turer Noritazeh has been con-firmed as a keynote speaker at the Glassman Middle East hol-low glass conference
Noritazehrsquos Director Saeed
Kalafchi will give a 20-min-ute overview of the Iranian glass industry and provide an update on Noritazeh and its recent developments
Other speakers at the hol-
low glass conference include glass container manufacturer Frigoglass inspection compa-ny Tiama Pneumofore IRF Europa and French refracto-ries group Sefpro
Interglass and Pennekamp form LATAM partnership
Mexican group Interglass has formed a partnership with German lehrs company Pen-nekamp
The new partnership will see Interglass introduce and push Pennekamprsquos range of prod-ucts and equipment through-out the entire LATAM region
Jose Luis Velez Interglass Managing Director said ldquoWersquore very optimistic about
the success that this collabora-tion will bring to both compa-nies as Pennekamprsquos top tech-nology perfectly complements our solutions portfolio
ldquoWe are sure that this new partnership will be very pros-perous and that it will main-tain us on the right track to lead the LATAM market on be-half of all the companies that we represent and work withrdquo
March newsindd 1 31116 210 PM
International News
Glass International March 2016
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NEWS IN BRIEF
Borosilicate glassrsquo 125th anniversaryExactly 125 years ago Otto Schott the founder of the technology group Schott discovered borosilicate glass and created the basis for high-tech applications in the 21st century
The glass is used in a variety of applications from streaming of sports events to high-tech material research These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors
Thai Glass forms partnership with XparThai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry
The partnership is the crown on the co-operation which started two years ago between TGI which is the container glass manufacturing subsidiary of Berli Jucker in Thailand and Xpar Vision based in The Netherlands
The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera The trial was executed at the TGI production facility at Saraburi With the IR-D camera system all bottles are inspected in real time to detect critical defects
Libbey reports 35 drop in sales in 2015US tableware manufacturer Libbey reported a full year sales drop of 35 in 2015 compared to the prior year
In its full year financials for 2015 it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada
It said sales performance in the US and Canada last year was led by a 75 increase in sales within the segmentrsquos foodservice channel
For 2016 Libbey forecast a sales growth of 1 from $8223 million to $830 million
Ground clearing begins at Ethiopian bottling plantAtlasrsquo 100 owned subsid-iary East Africa Packaging Holdings (lsquoEAPHrsquo) is building a glass bottle manufacturing facility 45km north of Ethio-piarsquos capital Addis Ababa
The plant will have the ca-pacity to produce 105 million 330ml bottles a year
Named the lsquoChancho Pro-jectrsquo Atlas has commenced ground clearing at the site and held a ceremony to com-memorate the event (pictured with Atlasrsquo CEO Carl Esprey pictured second from left)
Commissioning of the fa-cility has been scheduled for 2018 with full production tar-geted for early 2019
Levelling of the 55 acre site has begun and the topsoil has been stripped
The Chancho Project site is located in an established in-dustrial area that is serviced by excellent road infrastruc-ture as well as power
Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropri-ate grades of silica sand and
limestone are available in de-posits 30km away from the site
An initial pre-feasibility study was completed at the Chancho Project and re-turned positive results
A full feasibility study is now being conducted in tandem with local and internation-al engineering consultants which is close to completion
The total capital expend-iture is estimated at US$42 million to be funded on a staged basis by a mixture of debt from local development banks other debt providers
industrial partners and equityFor the last five years due to
increased consumer demand and a young demographic Ethiopia has been attracting investment from internation-al beverage companies with more than $500 million in-vested to date
Beer production has been growing at a CAGR of 143 over the last 14 years with an additional 47 capacity cur-rently under construction
The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports
Record year for UK electric melting specialistUK-based electric melting spe-cialist Electroglass has report-ed a ten-year record in its 2015 results
ldquoDespite uncertainty and slow-down in a number of world markets we have had an excellent yearrdquo said Managing Director Richard Stormont
ldquoAll-electric furnace and forehearths projects for fluo-ride opal tableware glass in south Asia in particular have been significant contributors
to this along with borosili-cate electric forehearths work in the USA gas-to-electric soda-lime forehearth conver-sions in South Korea electric boosting projects in Indonesia and elsewhere and contin-uing development and sales of our Precision Control Bub-bling Systems
ldquoAlso holding up well are sales of hardware notably the Molycool and Vertical Splash-guard ranges of electrode
holders and our dry-type fore-hearth electrodesrdquo he added
ldquoThe rest of 2016 sees the commissioning of several re-cently supplied systems and work is expected to start on a number of significant new projects for the companyrdquo
Electroglass will be exhib-iting at the upcoming Glass-man Middle East show in Abu Dhabi on the 10th and 11th May
March newsindd 2 31116 210 PM
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
+ TECHNOLOGY OMCO uses tailored technology to weld and machine moulds plungers and neck rings
+ FLEXIBILITY OMCO uses efficient manufacturing processes enabling quick turnarounds for urgent jobs
+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
= QUALITY PROMPTLY DELIVERED AT A COMPETITIVE PRICE
MOULDSHOPS OMCO BELGIUM I OMCO AUSTRIA I OMCO UK I OMCO CROATIA I OMCO ISTANBUL I OMCO ROMANIA FOUNDRIES OMCO BELGIUM I OMCO SLOVENIA
OMCOLEADING MOULD MAKERTO THE GLASS WORLD
International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
Tomorrows Technology Today
Electro-heat solution for glassFIC
The Worlds Number One in Furnace Technology
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
ww
gla
ss-i
nter
nati
onal
com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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-int
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
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COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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wm
otim
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
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Lab-precision volume measurement at the line
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
All in one
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A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
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International News
Glass International March 2016
5
Technology suppliers sign up for Middle East hollow glass event
NEWS IN BRIEF
Vitro sales boosted 22Growth in its container and flat glass businesses helped Vitro grow sales by 22
The Mexican company reported that the growth in the construction and automotive sectors as well as strong export and domestic sales had boosted business in the final quarter of 2015
Consolidated net sales increased 222 to US$229 million in the quarter it reported in its quarter four 2015 financials
Vitro CEO Mr Adrian Sada Cueva said ldquoThe strong dynamics of the construction market driven by shortages in Mexico and the economic recovery in the US coupled with the acquisition of new customers and increased exports of glass for the automotive sector and strong sales volumes in the pharmaceutical industry were the main factors that boosted sales this quarterrdquo
Frigoglass terminates GZI sale Frigoglass has terminated its agreement to sell its glass business in Dubai and Nigeria to GZ Industries (GZI)
The agreement was signed with GZI in May 2015 but a condition of the terms was not met GZI did not secure the necessary level of debt financing for the acquisition as a result of a change in regulations that restricts the ability to leverage Beta Glass and the adverse economic conditions in Nigeria
Amended offers were made by GZI but these were declined by Frigoglassrsquo Board of Directors
PPG sells PGW stakePPG is to sell 40 of its stake in Pittsburgh Glass Works (PGW)
The sale is in connection with LKQ Corporationrsquos plan to buy PGW which is expected to be completed by the end of the second quarter this year
PPG has held a minority interest in PGW since 2008 when it completed the sale of its automotive glass and services business to PGW
Several of the hollow glass in-dustryrsquos leading technology suppliers have confirmed their presence at the Glassman Mid-dle East event
German company Penneka-mp and UK group Electroglass have each taken a booth at the exhibition
They will be joined by French inspection group Tia-ma and Anderman Ceramics who will both present papers at the parallel conference
Pennekamp manufactures equipment for thermal pro-cesses (lehrs) as well as other
product areas within the glass industry
Electroglass has been in-volved in electric glass melt-ing technology since 1976 Its core activities are the develop-ment design engineering and supply of electric glass melting and conditioning systems and related equipment
Tiama is a provider of in-spection solutions for the hollow glass industry and will provide an update about its vi-sion product range
Anderman Ceramicsrsquo Gary Hateley will present a paper
titled Supplying refractory in-sulation for furnace linings
Glassman Middle East is a free to attend exhibition and conference dedicated to the hollowcontainertablewarespeciality glass sectors
It takes place on May 10 and 11 in Abu Dhabi UAE and vis-itors will include glass man-ufacturers from the region associations and technology suppliers
For more information visit wwwglassmaneventscommid-east
Iranian manufacturer Noritazeh confirmed as keynote speakerIranian tableware manufac-turer Noritazeh has been con-firmed as a keynote speaker at the Glassman Middle East hol-low glass conference
Noritazehrsquos Director Saeed
Kalafchi will give a 20-min-ute overview of the Iranian glass industry and provide an update on Noritazeh and its recent developments
Other speakers at the hol-
low glass conference include glass container manufacturer Frigoglass inspection compa-ny Tiama Pneumofore IRF Europa and French refracto-ries group Sefpro
Interglass and Pennekamp form LATAM partnership
Mexican group Interglass has formed a partnership with German lehrs company Pen-nekamp
The new partnership will see Interglass introduce and push Pennekamprsquos range of prod-ucts and equipment through-out the entire LATAM region
Jose Luis Velez Interglass Managing Director said ldquoWersquore very optimistic about
the success that this collabora-tion will bring to both compa-nies as Pennekamprsquos top tech-nology perfectly complements our solutions portfolio
ldquoWe are sure that this new partnership will be very pros-perous and that it will main-tain us on the right track to lead the LATAM market on be-half of all the companies that we represent and work withrdquo
March newsindd 1 31116 210 PM
International News
Glass International March 2016
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NEWS IN BRIEF
Borosilicate glassrsquo 125th anniversaryExactly 125 years ago Otto Schott the founder of the technology group Schott discovered borosilicate glass and created the basis for high-tech applications in the 21st century
The glass is used in a variety of applications from streaming of sports events to high-tech material research These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors
Thai Glass forms partnership with XparThai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry
The partnership is the crown on the co-operation which started two years ago between TGI which is the container glass manufacturing subsidiary of Berli Jucker in Thailand and Xpar Vision based in The Netherlands
The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera The trial was executed at the TGI production facility at Saraburi With the IR-D camera system all bottles are inspected in real time to detect critical defects
Libbey reports 35 drop in sales in 2015US tableware manufacturer Libbey reported a full year sales drop of 35 in 2015 compared to the prior year
In its full year financials for 2015 it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada
It said sales performance in the US and Canada last year was led by a 75 increase in sales within the segmentrsquos foodservice channel
For 2016 Libbey forecast a sales growth of 1 from $8223 million to $830 million
Ground clearing begins at Ethiopian bottling plantAtlasrsquo 100 owned subsid-iary East Africa Packaging Holdings (lsquoEAPHrsquo) is building a glass bottle manufacturing facility 45km north of Ethio-piarsquos capital Addis Ababa
The plant will have the ca-pacity to produce 105 million 330ml bottles a year
Named the lsquoChancho Pro-jectrsquo Atlas has commenced ground clearing at the site and held a ceremony to com-memorate the event (pictured with Atlasrsquo CEO Carl Esprey pictured second from left)
Commissioning of the fa-cility has been scheduled for 2018 with full production tar-geted for early 2019
Levelling of the 55 acre site has begun and the topsoil has been stripped
The Chancho Project site is located in an established in-dustrial area that is serviced by excellent road infrastruc-ture as well as power
Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropri-ate grades of silica sand and
limestone are available in de-posits 30km away from the site
An initial pre-feasibility study was completed at the Chancho Project and re-turned positive results
A full feasibility study is now being conducted in tandem with local and internation-al engineering consultants which is close to completion
The total capital expend-iture is estimated at US$42 million to be funded on a staged basis by a mixture of debt from local development banks other debt providers
industrial partners and equityFor the last five years due to
increased consumer demand and a young demographic Ethiopia has been attracting investment from internation-al beverage companies with more than $500 million in-vested to date
Beer production has been growing at a CAGR of 143 over the last 14 years with an additional 47 capacity cur-rently under construction
The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports
Record year for UK electric melting specialistUK-based electric melting spe-cialist Electroglass has report-ed a ten-year record in its 2015 results
ldquoDespite uncertainty and slow-down in a number of world markets we have had an excellent yearrdquo said Managing Director Richard Stormont
ldquoAll-electric furnace and forehearths projects for fluo-ride opal tableware glass in south Asia in particular have been significant contributors
to this along with borosili-cate electric forehearths work in the USA gas-to-electric soda-lime forehearth conver-sions in South Korea electric boosting projects in Indonesia and elsewhere and contin-uing development and sales of our Precision Control Bub-bling Systems
ldquoAlso holding up well are sales of hardware notably the Molycool and Vertical Splash-guard ranges of electrode
holders and our dry-type fore-hearth electrodesrdquo he added
ldquoThe rest of 2016 sees the commissioning of several re-cently supplied systems and work is expected to start on a number of significant new projects for the companyrdquo
Electroglass will be exhib-iting at the upcoming Glass-man Middle East show in Abu Dhabi on the 10th and 11th May
March newsindd 2 31116 210 PM
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
+ TECHNOLOGY OMCO uses tailored technology to weld and machine moulds plungers and neck rings
+ FLEXIBILITY OMCO uses efficient manufacturing processes enabling quick turnarounds for urgent jobs
+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
= QUALITY PROMPTLY DELIVERED AT A COMPETITIVE PRICE
MOULDSHOPS OMCO BELGIUM I OMCO AUSTRIA I OMCO UK I OMCO CROATIA I OMCO ISTANBUL I OMCO ROMANIA FOUNDRIES OMCO BELGIUM I OMCO SLOVENIA
OMCOLEADING MOULD MAKERTO THE GLASS WORLD
International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
Tomorrows Technology Today
Electro-heat solution for glassFIC
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G L A S S Q U A L I T YFives is a leading provider of glass technologies for the most demanding applications ultra-thin automotive pharmaceutical fiber solar crystal and speciality glass We contractually guarantee the productivity and environmental performance of your plant for secured profitability of your investmentWith over 60 years of experience in the glass industry Fives designs engineers manufactures installs tests and commissions glass equipment in a wide range of glass processes and applications all over the worldTrust Fives professionals to enhance your plantrsquos performance and competitiveness and to optimize your investmentglassfivesgroupcom wwwfivesgroupcom
FIVES PRIUMreg TECHNOLOGY THE ULTIMATE ADDED VALUE TO YOUR INVESTMENT
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Glass International March 2016
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A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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28
Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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fuel consumption
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
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fi rst In practice however discontinued products
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competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Messages Notes
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Laboratory Mould
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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International News
Glass International March 2016
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NEWS IN BRIEF
Borosilicate glassrsquo 125th anniversaryExactly 125 years ago Otto Schott the founder of the technology group Schott discovered borosilicate glass and created the basis for high-tech applications in the 21st century
The glass is used in a variety of applications from streaming of sports events to high-tech material research These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors
Thai Glass forms partnership with XparThai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry
The partnership is the crown on the co-operation which started two years ago between TGI which is the container glass manufacturing subsidiary of Berli Jucker in Thailand and Xpar Vision based in The Netherlands
The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera The trial was executed at the TGI production facility at Saraburi With the IR-D camera system all bottles are inspected in real time to detect critical defects
Libbey reports 35 drop in sales in 2015US tableware manufacturer Libbey reported a full year sales drop of 35 in 2015 compared to the prior year
In its full year financials for 2015 it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada
It said sales performance in the US and Canada last year was led by a 75 increase in sales within the segmentrsquos foodservice channel
For 2016 Libbey forecast a sales growth of 1 from $8223 million to $830 million
Ground clearing begins at Ethiopian bottling plantAtlasrsquo 100 owned subsid-iary East Africa Packaging Holdings (lsquoEAPHrsquo) is building a glass bottle manufacturing facility 45km north of Ethio-piarsquos capital Addis Ababa
The plant will have the ca-pacity to produce 105 million 330ml bottles a year
Named the lsquoChancho Pro-jectrsquo Atlas has commenced ground clearing at the site and held a ceremony to com-memorate the event (pictured with Atlasrsquo CEO Carl Esprey pictured second from left)
Commissioning of the fa-cility has been scheduled for 2018 with full production tar-geted for early 2019
Levelling of the 55 acre site has begun and the topsoil has been stripped
The Chancho Project site is located in an established in-dustrial area that is serviced by excellent road infrastruc-ture as well as power
Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropri-ate grades of silica sand and
limestone are available in de-posits 30km away from the site
An initial pre-feasibility study was completed at the Chancho Project and re-turned positive results
A full feasibility study is now being conducted in tandem with local and internation-al engineering consultants which is close to completion
The total capital expend-iture is estimated at US$42 million to be funded on a staged basis by a mixture of debt from local development banks other debt providers
industrial partners and equityFor the last five years due to
increased consumer demand and a young demographic Ethiopia has been attracting investment from internation-al beverage companies with more than $500 million in-vested to date
Beer production has been growing at a CAGR of 143 over the last 14 years with an additional 47 capacity cur-rently under construction
The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports
Record year for UK electric melting specialistUK-based electric melting spe-cialist Electroglass has report-ed a ten-year record in its 2015 results
ldquoDespite uncertainty and slow-down in a number of world markets we have had an excellent yearrdquo said Managing Director Richard Stormont
ldquoAll-electric furnace and forehearths projects for fluo-ride opal tableware glass in south Asia in particular have been significant contributors
to this along with borosili-cate electric forehearths work in the USA gas-to-electric soda-lime forehearth conver-sions in South Korea electric boosting projects in Indonesia and elsewhere and contin-uing development and sales of our Precision Control Bub-bling Systems
ldquoAlso holding up well are sales of hardware notably the Molycool and Vertical Splash-guard ranges of electrode
holders and our dry-type fore-hearth electrodesrdquo he added
ldquoThe rest of 2016 sees the commissioning of several re-cently supplied systems and work is expected to start on a number of significant new projects for the companyrdquo
Electroglass will be exhib-iting at the upcoming Glass-man Middle East show in Abu Dhabi on the 10th and 11th May
March newsindd 2 31116 210 PM
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
+ TECHNOLOGY OMCO uses tailored technology to weld and machine moulds plungers and neck rings
+ FLEXIBILITY OMCO uses efficient manufacturing processes enabling quick turnarounds for urgent jobs
+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
= QUALITY PROMPTLY DELIVERED AT A COMPETITIVE PRICE
MOULDSHOPS OMCO BELGIUM I OMCO AUSTRIA I OMCO UK I OMCO CROATIA I OMCO ISTANBUL I OMCO ROMANIA FOUNDRIES OMCO BELGIUM I OMCO SLOVENIA
OMCOLEADING MOULD MAKERTO THE GLASS WORLD
International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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10
NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
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The Worlds Number One in Furnace Technology
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FIC - Cube ad 2016 20216 1200 Page 1
G L A S S Q U A L I T YFives is a leading provider of glass technologies for the most demanding applications ultra-thin automotive pharmaceutical fiber solar crystal and speciality glass We contractually guarantee the productivity and environmental performance of your plant for secured profitability of your investmentWith over 60 years of experience in the glass industry Fives designs engineers manufactures installs tests and commissions glass equipment in a wide range of glass processes and applications all over the worldTrust Fives professionals to enhance your plantrsquos performance and competitiveness and to optimize your investmentglassfivesgroupcom wwwfivesgroupcom
FIVES PRIUMreg TECHNOLOGY THE ULTIMATE ADDED VALUE TO YOUR INVESTMENT
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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-int
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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-int
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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-int
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
tiama ndashadvanced knowledge
If you need to simplify your life
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
distributors are offered with guarantees covering temperature stability thermal homogeneity and
fuel consumption
Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
or obsolete interfaces can seriously impact your
competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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46
A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
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Messages Notes
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Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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Unit 43 Evans Business Centre Easter Inch Bathgate EH48 2EH Scotland UK
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
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ADV_bdf_2016_OKindd 1 050216 1237
+ ENGINEERING OMCO has an experienced engineering and design team ready to handle any project+ MATERIAL OMCO has two foundries ensuring a flexible supply of quality castings
+ TECHNOLOGY OMCO uses tailored technology to weld and machine moulds plungers and neck rings
+ FLEXIBILITY OMCO uses efficient manufacturing processes enabling quick turnarounds for urgent jobs
+ CAPACITY OMCO has six production plants with enough capacity to meet all your needs
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International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
Tomorrows Technology Today
Electro-heat solution for glassFIC
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FIVES PRIUMreg TECHNOLOGY THE ULTIMATE ADDED VALUE TO YOUR INVESTMENT
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Glass International March 2016
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A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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28
Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
distributors are offered with guarantees covering temperature stability thermal homogeneity and
fuel consumption
Are yours
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
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fi rst In practice however discontinued products
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competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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International News
Glass International March 2016
Orora to invest $42MOrora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant to in-crease capacity
The increase in output will be approximately 60 million bottles per annum
To maintain production rates commissioning will be progressive and is ex-pected to commence in the
second half of 2016 with completion expected in the first half of 2017
Approximately 35 of the cash flow will be in-vested in FY16 with the balance in FY17
The company is also as-sessing a potential invest-ment of a further $10-$15 million in an automated warehouse
Ororarsquos glass business
is experiencing increased demand within the wine segment driven by the re-patriation of wine that is currently bottled offshore
ldquoThe glass business is al-ready in an oversold posi-tion and this investment will further enhance Oro-rarsquos ability to service the increased demand from customersrdquo said Nigel Gar-rard Ororarsquos CEO
Vetropack orders SIL systemSwiss group Vetropack closed a deal with Vertechrsquo early this year to install SIL2016 in the companyrsquos recently acquired Italian plant Trezzano sul Naviglio
Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market
Trezzano sul Naviglio currently produces around 140000 tons of glass packaging every year for the food and beverage in-dustry and used Vertechrsquo solutions for production line monitoring and qual-ity control on some of its lines
Vetropackrsquos decision to extend SIL to the remain-
ing production lines and the mould department is part of the companyrsquos corporate strategy to gain significant market share as well as expand its current product portfolio and cus-tomer base
SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter
Siam Glassrsquos vacuum system
Italian company Pneumo-fore has installed a vacuum system at Siam Glassrsquos Ro-jana plant in Thailand
The vacuum system used in glass forming has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21600 more bottles each day
Siam Glass runs three plants in Thailand making
energy drink bottles of var-ying size
The challenge for Pneu-mofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum Only one of the three IS lines was modified and configured as a lsquotest benchrsquo for vacuum
The results convinced the management to ex-tend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants
Three UV50 rotary vane vacuum pumps are con-stantly in operation at the Rojana plant
They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption
Production performance per IS line
37 TPD saveddayIS 7200 more bottlesdayISTotal of
21600 more bottles produced in the plantday
BEFOREWeight (g) 145 140 -335
097130
520945
515932
Speed (bottlemin)Efficiency ()
AFTER DEVIATION
March newsindd 3 31116 210 PM
Making potentials visible
E20001-F120-T112-X-7600_Ad_Glass_A4indd 1E20001-F120-T112-X-7600_Ad_Glass_A4indd 1 200415 1016200415 1016
International News
Glass International March 2016
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10
NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
Even thehardestpuzzles have asolution
Tomorrows Technology Today
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The Worlds Number One in Furnace Technology
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FIC - Cube ad 2016 20216 1200 Page 1
G L A S S Q U A L I T YFives is a leading provider of glass technologies for the most demanding applications ultra-thin automotive pharmaceutical fiber solar crystal and speciality glass We contractually guarantee the productivity and environmental performance of your plant for secured profitability of your investmentWith over 60 years of experience in the glass industry Fives designs engineers manufactures installs tests and commissions glass equipment in a wide range of glass processes and applications all over the worldTrust Fives professionals to enhance your plantrsquos performance and competitiveness and to optimize your investmentglassfivesgroupcom wwwfivesgroupcom
FIVES PRIUMreg TECHNOLOGY THE ULTIMATE ADDED VALUE TO YOUR INVESTMENT
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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-int
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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-int
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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-int
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
ww
wg
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-int
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alc
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
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competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
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any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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International News
Glass International March 2016
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
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Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
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Thin Glass
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Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
ww
wg
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-int
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tion
alc
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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-int
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alc
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
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2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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for Tableware and Stemware
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ANNEALING amp DECORATING LEHRS for Containers and Tableware
KBA-KAMMANN GmbH Bergkirchener Str 228D-32549 Bad Oeynhausen (Germany)
Fon +49 (0) 5734 5140-0 Fax +49 (0) 5734 5140-5130mailkba-kammanncom wwwkba-kammanncom
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2 Eastbourne TerraceLondon W2 6LG UK
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Global CombustionSystems
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Unit 43 Evans Business Centre Easter Inch Bathgate EH48 2EH Scotland UK
Tel+44 (0) 1506 657310Fax +44 (0) 8704 799975Email SalesglobalcombustioncomWeb wwwglobalcombustioncom
TIAMA ZA des Plattes 1 Chemin des Plattes 69390 Vourles France
Tel +33 (0) 4 37 20 15 00Fax +33 (0) 4 78 07 94 50
Email marketingtiamacomWebsitewwwtiamacom
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Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812Email salesmontselascouk wwwmontselascouk
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T+44 (0) 1737 855136to book your space
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
International News
Glass International March 2016
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NEWS IN BRIEF
Glassman sign-upsMega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show Glassman Middle East
The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference
The company represents a number of leading European container glass suppliers including Tiama Antonini Revimac Ruitai and Messerssi
They will be joined by German group LWN Lufttechnik which has taken a 9m2 stand at the exhibition
Furnace life website PaneraTech has released a dedicated website for Smart-Melter a technical solution for furnace life optimisation
SmartMelter provides asset management for glass melting furnaces
The website allows glass manufacturers to learn more about the technology and outlines service and licensing options The website is wwwsmartmeltercom
Interglass gas crisis Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufac-turer Interglass
The gas company said it would disconnect Interglass due to unpaid debts amounting to 1117400000 of Kyrgyzstan soms ($15 million)
According to Gazprom Kyrgyzstan it has not stopped trying to settle the matter out of court and has tried to initiate meetings with Interglass
It has to date not turned off the gas supply due to the social importance of the plant
PneumoforeIn the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason Pneumoforersquos location was labelled incorrectly in a map of Italy
The company is based in the north west of the country rather than the north east
Be first with the news VISIT wwwglass-internationalcom for daily news updates
All full stories can be found on our website wwwglass-internationalcomnewsr 1 Iranrsquos Nafis Glass commissions glass plantr 2 Borosilicate glass celebrates 125th anniversaryr 3 Ground clearing begins at Ethiopian bottling plantr 4 Interview with Shandong Huapeng General Manager Mr Zhang De Huar 5 Wine and spirits help boost O-I volumes by 3 in 2015r 6 Ardagh Glass launches updated educational programmer 7 Quantum and Interglass form partnershipr 8 Impianti Novopac latest company to sign up for hollow glass exhibitionr 9 Frigoglass terminates sale to GZ Industriesr 10 Glass school in China
Top 10 stories in the newsOur most popular news items as determined by our website traffic
Heye welcomes Stoumllzle expertsHeye International welcomed senior production experts from the Stoumllzle group to Obernkirchen Germany re-cently to discuss their develop-ment priorities
Stoumllzle is an important cus-tomer for hot and cold end equipment and Heyersquos techni-cal team were on hand to dis-cover the customerrsquos priorities
Ten senior members of Stoumll-zlersquos multinational production team attended the meeting in Obernkirchen where Gerd Muumlller Cold End Manager presented the grouprsquos latest developments including the creation of a centre of excel-lence for cosmetic flacons at the Masnieres plant in France
As well as discussing best
practice solutions for the glass container production process the workshop addressed future inspection priorities
This included a debate about which cold end inspection functions could be moved to the hot end the elements re-quired in the lsquoidealrsquo inspection machine and the potential for automatic job changes
Bastuumlrk Glass selects SorgGerman company Sorg said it was honoured to have been selected as the furnace sup-plier by Bastuumlrk Glass for its greenfield project in Turkey
Bastuumlrk is a new player to the glass industry and is build-ing a site in Malatya in the Eastern Province of Turkey
The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers
Sorg said it lsquowanted to thank Y amp H Foreign Trade Limited for its assistance in securing the order and Bastuumlrk Glass for placing its trust in usrsquo
The Bastuumlrk delegation at the Sorg site in Lohr am Main Germany
March newsindd 4 31116 210 PM
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Glass International March 2016
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A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
ww
gla
ss-i
nter
nati
onal
com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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-int
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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-int
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
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VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
or obsolete interfaces can seriously impact your
competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
ww
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
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Lab-precision volume measurement at the line
Multi-line support
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嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Tomorrows Technology Today
Electro-heat solution for glassFIC
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G L A S S Q U A L I T YFives is a leading provider of glass technologies for the most demanding applications ultra-thin automotive pharmaceutical fiber solar crystal and speciality glass We contractually guarantee the productivity and environmental performance of your plant for secured profitability of your investmentWith over 60 years of experience in the glass industry Fives designs engineers manufactures installs tests and commissions glass equipment in a wide range of glass processes and applications all over the worldTrust Fives professionals to enhance your plantrsquos performance and competitiveness and to optimize your investmentglassfivesgroupcom wwwfivesgroupcom
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
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Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
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Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
ww
gla
ss-i
nter
nati
onal
com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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-int
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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itlsquos time forTiama Hot Systems gives you information at the hot end to
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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Are yours
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
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Messages Notes
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Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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Sheppee Classified advertpdf 1 04022016 103415
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CLASSIFIEDSindd 1 31016 957 AM
倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
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Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
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Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
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Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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-int
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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-int
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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wg
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-int
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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wg
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-int
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
or obsolete interfaces can seriously impact your
competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
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any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
available today
PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Glass International March 2016
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13
A Chinese group with global plans
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer Shandong Huapeng Glass The company has its headquarters and two factories in Shandong one factory in Liaoning one in Shansi one in Anhui and one in Zhejiang
Continuedgtgt
Shandong Huapeng Glass consists of Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and
Shanxi Huanpeng Shuita GlassIt specialises in RampD production and sales of all
kinds of medium and top grade glassware and glass bottles
Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA Italy Germany France and Belgium and are of the highest international advanced level The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with RampD ability
A total of 37 types of its glassware products have won the design patent certifi cation issued by the Sate Intellectual Property Offi ce and the product quality has reached the domestic leading level and an international advanced level It is the main supplier to Metro Wal Mart Carrefour Trust-mart and many other well-known international supermarkets
Could you briefl y present the current Chinese glass packaging marketMr Zhang De Hua The Chinese glass industry faces strong consolidation the new environmental regulations have made it diffi cult for small glass factories to survive The market leaders will certainly shape tomorrowrsquos glass industry
Could you please introduce your com-pany Shandong Huapeng Glass and your strategy at this timeShandong Huapeng is one of Chinarsquos leaders in glass packaging and the largest manufacturer of crystal-like tableware We have taken advantage of todayrsquos industry evolution and our company has opened new factories all over China At this stage we already have more than seven glass factories Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales For this reason Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well
In 2015 Huapeng upgraded one complete new production line with Tiamarsquos latest inspection machines MCAL4 (sidewall amp dimensional) MULTI4 (fi nish amp base) and MX4 (carousel technology) equipped with ATLAS systems (non-contact check detection) Before May 2016 Huapeng will install an additional 12 machines MCAL4 MULTI4 and MX4 with ATLAS
What benefi ts has the Tiama equip-ment brought to Shandong Huapeng We have achieved a lot of quality inspection improvement for example we have drastically reduced the quantity of cracks Our global product standard and our overall product quality have both surged We are using the most advanced
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Chinese
overview
A Chinese group with global plans
Mr Zhang De Hua is
chairman and General
Manager of Chinese
container and tableware
manufacturer Shandong
Huapeng Glass
Company overview Shandong Huapeng
A Chinese group with global intentions
Company profile shandong 2 pagesindd 1 31116 215 PM
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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wg
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
distributors are offered with guarantees covering temperature stability thermal homogeneity and
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
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step in
With more than 40 yearsrsquo experience in automation
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drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
available today
PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
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Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
Company overview Shandong Huapeng
Glass International March 2016
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14
technology for detection which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past We are also monitoring and inspecting the glass thickness in our glassware as a general results we have no broken ware delivered to customers We have received appraisal from our most demanding North American foreign customers
How important is automation and au-tomated equipment to your company Automation is very important for our company as it is directly linked with quality Our customers are very demanding for quality and automated equipment has helped us to achieve our productivity targets while improving our quality
What is the Shandong Huapeng main range of products Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging as well as all kind of bottles shapes for wine liquors and olive oils
ldquoThe Tiama
inspection
equipment has
helped us achieve
the highest quality
standards required
by our customers
and ensures our
product safetyrdquo
We manufacture for Chinarsquos market but also a large share of our production is for export market in the APEC regions These containers require a high quality level of inspection The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety
Finally can you briefly tell me about Huapengrsquos tableware capacity Yes that is right Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass We provide our products to famous five stars hotels in China as well as export them worldwide our main markets are South Korea Japan the United States Canada and Russia r
Shandong Huapeng Glass Shandong Chinahttpenhuapengglasscom
Tiama Vourles near Lyon Francewwwtiamacom
An overview of its head-
quarters in Shandong
The company has installed
the latest inspection equip-
ment from French company
Tiama
Chinese
overview
Company profile shandong 2 pagesindd 2 31116 216 PM
MULTIPOINTWALL THICKNESS
wwwheye-internationalcom
Covers all critical areas of a container
Flexible combination with single point sensor
Superior chromatic confocal method
Independent of measuring range and angle
Suitable for round and non-round containers
MULTIPOINT THICKNESS SENSOR MTS1005STAND-ALONE OR INTEGRATED IN HEYE SMARTLINE
WE ARE GLASS PEOPLE
RZ_HEY_AZ_MTS10_A4_Kanchindd 1RZ_HEY_AZ_MTS10_A4_Kanchindd 1 030216 1152030216 1152
Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
Glass is our PassionEME Maschinenfabrik Clasen GmbH middot E-Mail contactemede middot wwwemede
Thin Glass
Tableware
Fibre Glass
Float Glass
We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
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With more than 40 yearsrsquo experience in automation
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any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
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Glass containers are one of the most important packaging materials in the food beverage medical and cosmetic industry with a huge variety of shapes sizes and colors
Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
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Thin Glass
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Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
ww
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tion
alc
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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28
Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
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With more than 40 yearsrsquo experience in automation
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any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Single or multi furnace batch plantsHigh quality container glass requires a precise batch composition and accurate cullet addition One or several furnaces with different glass types can be served from one batch plant without contamination ndash Just perfect
From raw material delivery to batch chargingWe manage all your raw materials including cullet and provide sophisticated batch charging technology Com-pletely sealed doghouses less dust less emissions less energy losses and now also modular for full redundancy
As the leading supplier of batch plants cullet handling equipment and batch charging technology EME has developed and successfully delivered specifi c solutions for the container glass industry
Enjoy these benefi ts ndash go with EME
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We have solutions for all types of glass production
Container Glass
Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
ww
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tion
alc
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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28
Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
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With more than 40 yearsrsquo experience in automation
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any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Country profi le China
Glass International March 2016
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17
Chinarsquos container industry set to rise to higher peaks
Ahead of the much-anticipated China Glass show in Shanghai Seema Gahlut provides an overview of the Chinese container glass industry which in recent years has grown at an astonishing rate
Continuedgtgt
ldquoBy 2022
China is
expected to
become the
largest global
consumer of
food packaging
surpassing the
USrdquo
Producing around 26 million tons per year the Chinese container glass industry has more than 900 large medium and small
container glass producers and grew at a CAGR of more than 12 from 2000-2014 Production fi gures for 2015 are not yet available but it is anticipated that growth fi gures remained close to 10 on a year-to-year basis
The industry has achieved this gigantic growth on the back of brisk urbanisation a rise in disposable incomes for a vast section of the population and increased spending on food and beverages An increased focus on healthcare has also been an important spur for the development of the industry
The top 10 provinces contributed 85 to the countryrsquos overall container glass production in 2014 with most production based in the coastal provinces including Shandong Zhejiang Guangdong Jiangsu and Fujian The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation More manufacturing plants have set-up up along the coastal provinces to ship goods overseas which in turn has also reduced freight prices
Demand drivers Alcoholic and non- alcoholic beverages food and the pharmaceutical industry (in that order) are the largest demand drivers for container glass
Due to the complex nature of the Chinese container glass manufacturing industry it is diffi cult to evaluate the performance of each sub-segment on a numbers basis This is due to the batch production nature of many of the mid and small scale producers which often operate on a lsquoby demandrsquo basis
Alcoholic beverages hold the largest share
of container glass consumption despite the industryrsquos hold on beer packaging slipping for several reasons Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry The profi t margins of glass-bottled beers are low compared to beer in cans and as a result a numbers of brewers have turned to metal packaging Consumers have also accepted canned packaging particularly in retail consumption due to the convenience of carrying
After beverages the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years The population has shifted to larger urban centres which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw minimally packaged items
By 2022 China is expected to become the largest global consumer of food packaging surpassing the US This is due to increased urbanisation higher personal incomes and an escalating interest in packaged foods PET packaging currently accounts for a large share of food packaging in China but with an increased purchasing power glass is expected to corner a share in the industry
The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory with the largest gains in the industry coming from these two sectors in recent years
OvercapacityThe establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity
Chinarsquos container industry set to rise to higher peaks
Chinese overviewindd 1 31116 1251 PM
Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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alc
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
distributors are offered with guarantees covering temperature stability thermal homogeneity and
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
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step in
With more than 40 yearsrsquo experience in automation
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drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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46
A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
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PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
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Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Country profile China
Glass International March 2016
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18Continuedgtgt
Lower than expected demand growth in recent years and the replacement of glass in some sub-segments by alternative forms of packaging have led to an overcapacity The overcapacity is more prominent in the mid and low end sub-segments of the industry
Schott Xin Kang GlassSchott is a German manufacturer of speciality glass products and is investing heavily in Chinarsquos container glass industry The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County Zhejiang province in July 2015 The company already owns two production facilities in China including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang
Schottrsquos expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50 The new pharmaceutical packaging facility is being constructed at Schott Xinkangrsquos site in Jinyun It will produce glass containers for injectable drugs including vials and ampoules and is scheduled for commissioning in 2017
Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles The company was established in 1970 and has its registered office in Zibo China
Shandong Pharmaceutical is one of Chinarsquos largest pharmaceutical packaging manufacturers It produces pharmaceutical glass such as moulded injectable vials glass tubing ampoules and tubular vial for injection It also produces container glass for cosmetics and the food amp beverage industries
The companyrsquos products are sold and distributed to domestic markets and to more than 1000 medical companies all over China It also has a presence in USA Europe India South Africa
Australia the Middle East Thailand Vietnam Pakistan and Syria
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country It comprises subsidiaries Huapeng Glass (Heze) Liaoning Huapeng Guangyuan Glass Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass It has an installed capacity of more than 240000 TPA of container glass and more than 40000 TPA of tableware glass
Yantai Changyu Glass CompanyA subsidiary of the largest wine producer in China Changyu Wine Yantai Changyu Glass Company produces almost 90 of the bottles needed for its parent companyrsquos wine packaging
Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country
Yantai Changyu has an installed capacity of more than 600000 tons of container glass a year It has seven furnaces and 20 production lines in operation at two sites in Shandong province The company is capable of producing products from 100ml to 6000ml with the blow-blow and press-blow technique
S No Company Location Production Capacity Product Segments
1 Yantai NBC Glass Packaging Shandong 140000 TPA Food amp Beverage
2 Shandong Pharmaceutical Glass Company Shandong 500000 TPA Pharmaceutical Glass
3 Linuo Glass Jinan 140000 TPA Pharmaceutical Glass
4 Yantai Changyu Glass Company Yantai Shandong Province 500000 TPA Alcoholic Beverages
5 Rockwood amp Hines Glass Factory Jiaxing 120000 TPA Alcholic Beverages amp Cosmetics
6 Kohler Glass Company Jiangsu 80000 TPA Food amp Beverage Industry
7 OMPI Pharmaceutical Packaging Company Jiangsu 180000 TPA Pharmaceutical Glass
8 Shandong Yuncheng Ruisheng Glass Co Ltd Yuncheng Shandong 160 000 TPA Beverage Industry
9 Xuzhou Dahua Glass Company Jiangsu 180000 TPA Cosmetics and Pharmaceuticals
10 Yammamura Glass Qinhuangdao Company Limited Jiangsu 200000 TPA Beverage Industry
11 Beijing Gerresheimer Glass Company Jiangsu 300000 TPA Pharmaceutical Glass
12 Shandong Heishan Glass Group Shandong 100000 TPA Beverage Industry
13 Zibo Baoxiang Glass Company Shandong 120000 TPA Beverage Industry
14 Shendong Shenhua Glass Joint Company Shandong 160000 TPA Food and Beverage Industries
15 Dalian Shengdao Glass Dalian 120000 TPA Food amp Beverage Industries
Table 1 Major Chinese container glass producers
ldquo[Schott]
will invest $33
million in
China in the
next three years
to increase its
overall
production
capacity in
the region by
50rdquo
Chinese overviewindd 2 31116 1251 PM
Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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20
Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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wg
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alc
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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itlsquos time forTiama Hot Systems gives you information at the hot end to
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
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step in
With more than 40 yearsrsquo experience in automation
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any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
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Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
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Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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otim
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Messages Notes
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Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Country profile China
Glass International March 2016
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19
ldquo[O-I] has
scaled down
its operations
considerably in
the country due
to the issue of
profitabilityrdquo
Xuzhou Rui Tai Glass CompanyLocated in the Mao economic development zones in the city of Xuzhou Jiangsu province Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country
Claiming to have lsquobest of its classrsquo equipment from some of the most reputable suppliers Rui Tai operates six furnaces and 42 production lines to produce 500000 tons of container glass per annum for beverage and food industries
Kohler Glass Bottle CompanyKohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province The company produces container glass in flint half flint green and amber colours
It can design and produce customised glass bottles according to customerrsquos requirements The company also carries out deep processing such as sand blasting silk screen printing glazed and transparent paints on glass bottles
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the countryrsquos container glass production The company owns Shenzhen Beauty Star Zhaoqing Tongchan Glass Technology Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800000 tons of glass through its subsidiaries
Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country Its major cosmetic packaging customers are PampG Shiseido Unilever Avon LrsquoOreal and Arrow
Its main beverage customers are Carlsberg Heineken Tsingtao Pearl River Haitian and other beer brewers
Owens-Illinois Owens-Illinois (O-I) which had strengthened its position in the industry via the acquisition of two domestic companies in 2010 has scaled down its operations considerably in the country due to the issue of profitability
According to an earlier press statement of
outgoing CEO Al Stroucken ldquoIn China there are more than 1000 bottle makers and many sell at prices that didnrsquot make economic sense to usrdquo
He added ldquoWe found it was difficult to compete profitablyhellipwith so many small playersrdquo conceding that the effort to produce on a large scale for domestic customers rather than multinationals with higher quality standards was ldquoa mistakerdquo
In one of his last investor meetings Mr Stroucken repeated the importance of the Chinese market He said ldquoI would say long term the trends in China still remain fairly positive But of course we are operating from a much more restricted basis than we have had in the past We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price levelrdquo
Slower growth Chinese container glass production has reached an unprecedented level of production although judging from recent trends in the Chinese and global economy there are tough times ahead
According to data reported by Chinarsquos National Bureau of Statistics (NBS) industrial production in the country rose 59 year-on-year in December 2015 slowing from a 62 increase the previous month The manufacturing sector expanded the most by 7 followed by mining (+14) In contrast electricity heat gas and water production and supply declined by 08 From January to December 2015 industrial output rose 61 On a month-on-month basis industrial output grew 041 Industrial production in China averaged 1272 from 1990 until 2015 reaching an all time high of 294 in August of 1994 and a record low of -211 in January 1990
The industrial output of the flat glass industry dropped by 86 year-on-year according to the NBS The slowdown in the flat glass industry is a result of central governmentrsquos strong commitment to slashing excess capacity and discouraging zombie factories ndash those unable to pay their debt and survive without outside support ndash which face greater challenges to survive this year
Container glass demand will drop in future due to Chinarsquos economic slowdown
Container producers have already made production cuts as demand from end users has dwindled Production levels in the segment have not dropped as sharply as those in the flat segment where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand But flat or low growth in the container sector cannot be ruled out r
China Glass takes place this year in Shanghai between April 11 and 14th
wwwchinaglass-expocom
Chinese overviewindd 3 31116 1251 PM
Company profi le FERVER
Glass International March 2016
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Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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alc
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
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GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
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COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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wm
otim
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
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Lab-precision volume measurement at the line
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倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
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Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
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Company profi le FERVER
Glass International March 2016
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Federation proves that glass recycling is not a waste
Continuedgtgt
Glass recycling collection rates in Europe have improved dramatically in the past 10 years In autumn last year the latest fi gures
showed more than 25 billion glass containers were recycled in the EU which is about 73 of all the bottles made in Europe
Terms such as recycling sustainability and lsquobeing greenrsquo have entered the public consciousness and most of us are aware of the benefi ts of recycling whether it be glass paper or food
It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation which was developed at the end of 2004 to represent the glass recycling companies of the continent
Promisingly the amount of glass recycled in Europe looks set to rise even further companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver
Greg Morris travelled to the Federation of Glass Recyclersrsquo (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe
Once they are members they will receive the benefi t of its expertise and be given information on how to develop their business It has 40 member companies represented in 18 countries 15 in the EU and three from outside the EU
Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey Poland Croatia Romania and even Canada
BackgroundFERVER represents European glass recyclers The majority of its members are from packaging glass but there is a substantial number of fl at glass recyclers who are represented
Like any traditional federation it helps its members develop business protects and informs them and promotes their activities at an EC and
Ferverrsquos member companies have invested heavily in machinery in order to supply glass
manufacturers high quality cullet
Company profile FERVERindd 1 31116 220 PM
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
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fi rst In practice however discontinued products
or obsolete interfaces can seriously impact your
competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Laboratory Mould
Vertech 15indd 2 31016 952 AM
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Fon +49 (0) 5734 5140-0 Fax +49 (0) 5734 5140-5130mailkba-kammanncom wwwkba-kammanncom
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Tel+44 (0) 1506 657310Fax +44 (0) 8704 799975Email SalesglobalcombustioncomWeb wwwglobalcombustioncom
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倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
All in one
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A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
Company profi le FERVER
Glass International March 2016
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21Continuedgtgt
national level When new legislation is discussed at a European level FERVER negotiates with the authorities to make it as acceptable as possible for its members The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level
A current piece of legislation is the Circular Economy package which is of huge importance to glass recyclers The package proposed by the European Commission sets glass recycling rates at 75 across Europe by the end of 2025 and 85 by the end of 2030 The legislation broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE has revised glass recycling targets in Europe
FERVERrsquos General Secretary Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough
ldquoThere is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe where they are a long way from reaching even existing targets
ldquoIt will take time for these countries It took a long time for them to realise the value of waste and it takes time education and fi nancial effort to organise a specifi c collection system to reach a valuable product for recyclingrdquo
In countries where recycling rates are low fi nancial measures from government such as landfi ll taxes will help boost recycling rates
Mr Ska has been in his current role for six years and said ldquoEastern European countries are very active but the problem they have is it is diffi cult to
get the source of the glass in their countries They can perfectly recycle any glass that they collect but the problem is the inputrdquo
He warns of European legislation becoming too strict causing the glass manufacturing industry to move to less regulated parts of the world
ldquoItrsquos a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world
Transport is not a cost at the moment so it is easy to import glass worldwide to Europe but it is not suitable to send untreated collected glass all over the world In the Circular Economy where sustainability and proximity are key terms it makes no sense to recycle material to send to other parts of the worldrdquo
Glass recycling rates vary greatly across Europe from 97 in Sweden and 88 in Germany to 38 in the Slovak Republic and 32 in Hungary Work has begun to improve rates in those countries and one of the benefi ts of being a FERVER member is that different countries swap best practice ideas
The EU Commission in its Circular Economy package proposes to change the defi nition of recycling At present recycling is considered as the moment of collection but the Circular Economy package has changed the defi nition and refers to the fi nal recycling process which means that the stream is re-integrated into the production chain Mr Ska admits there is a lot of work to do in eastern European countries but states that the majority of FERVER members are safe in terms of the Circular Economy package
ldquoMore than 90 of our membersrsquo production is sold as end of waste so we have already reached the end of waste status so what we are selling is no longer waste but a product That means recycledrdquo
Black glassThe improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers Each glass manufacturer wants to reduce its energy consumption and CO2 emissions so therefore asks for high quality input material
For recyclers it has required investment in more sophisticated sorting machines to sort out the non-glass such as ceramic stone and porcelain (CSP) and lead content in both crystal glass and in television screens One recent problem for recyclers has been the rise of trendy colourful glass bottles which are designed to stand out on the shelf against competitor drinks Some bottles such as black glass are so dark they are considered stones by optical sorting machines and are rejected
Mr Ska said ldquoThese bottles are recyclable if they go directly in a glassmakersrsquo oven but when it comes into the chain via collection in municipalities it is rejected by optical sorting machines or the recyclers
ldquoThere is a trend for bottles that stand out on the
Mr Ska
FERVERrsquos Secretary
General
Company profile FERVERindd 2 31116 220 PM
Company profi le FERVER
Glass International March 2016
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22
shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
ww
gla
ss-i
nter
nati
onal
com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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25
many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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26
Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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28
Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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Are yours
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
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step in
With more than 40 yearsrsquo experience in automation
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any IS machine in the market Now and in the future
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2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
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Company profi le FERVER
Glass International March 2016
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shelf but this marketing is bad for recycling The best product for us is a cylindrical bottle without a label and any colour but then you have an anonymous productrdquo
Glassmakers have been encouraged to be more aware of their packaging The recyclability has to be tested before launching a new product
For example a re-sealable cap with wire and ceramic can cause inclusions Metalised labels can also cause inclusions in a new bottle But glass cork rubber stoppers crown cork and well-designed aluminium caps are fi ne and sleeved labels are ideal for glass recycling Other challenges for recyclers are the design of bottles Glass bottles with a convex uneven or embossed shape make it diffi cult to check for failures on newly produced bottles RFID tags in labels can also cause inclusions
Opportunities Mr Ska is positive about the future of glass and of glass recycling He
believes the general concept of sustainability favours the glass sector compared to other types of packaging
ldquoSome foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass
ldquoThe new Circular Economy has clear targets and clear calculation methods so
the wrong reportage to Eurostats will no longer be a possibility It is certainly an
opportunity to promote recycling at a European level
ldquoWe are in contact with recyclers and authorities outside of Europe
that view Europe as an example of good recycling Glass is one of the best examples of recycling so we are an lsquoexample of the examplersquo We hope to promote outside of Europe the real recycling of glassrdquo
FERVER Brussels Belgium wwwfervereu
Latest fi gures show
more than 25 billion glass
container bottles a year were
recycled in Europe
Some of FERVERrsquos mem-
ber companies
Some bottles such as
black glass are so dark they
are considered stones by
optical sorting machines and
rejected
Company profile FERVERindd 3 31116 220 PM
SOLUTIONS FOR THE GLASS INDUSTRYFurnacesForehearthsRobotics
OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMSLOWEST NOX EMISSIONSHIGHER PRODUCT QUALITYENERGY SAVINGS2015 installations 410 tonsday - container glass - England270 tonsday - container glass - Estonia 18 tonsday - borosilicate glass - Ukraine220 tonsday - container glass - Italy 24 tonsday - borosilcate glass - Iran - refurbishing
GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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com
24
As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
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competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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GLASS SERVICE srl - ITALY tel+3905714442 wwwglassserviceit
Supplier profi le Zippew
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As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
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COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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wm
otim
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
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Lab-precision volume measurement at the line
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倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
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Supplier profi le Zippew
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As part of our series of profi les on German suppliers in the run up to glasstec 2016 Sally Love met with Dr Holger Zippe at the companyrsquos headquarters in Wertheim As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec and so was able to share his thoughts on the industryrsquos biggest event
Can you give us a brief history of ZippePut in a nutshell the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria on their wedding day At that time they worked for the Bohemian glass industry but after 1945 all this was gone and they left their home in Bohemia and went to Germany They made their way through Eastern Germany and fi nally settled in Wertheim We are happy they settled here because the location is fantastic for us ndash we are only 45 minutes from the airport which is a major asset because we can easily travel all around the world
In 1960 my father Alfred Zippe Jr built the fi rst automatic batch plant in Germany for a container glass company making bottles in Nienburg In 1964 we built our fi rst batch plant overseas and since then it has become a success story We work worldwide for glass factories and glass groups whenever they need a batch plant modifi cation or even a new batch plant We do not get all the orders but I feel we often get the big important orders We have a staff of 200 people all highly professional and with a lot of experience however we are still a young team with an average age of 36
Does being a family-run company affect Zippersquos core valuesCertainly yes We have many positive effects from being a family company One is with all our employees we work very closely together with a long-term perspective We have
A family affair
staff of 200 people all highly professional and with a lot of experience however we are still a young team with an
z Dr Holger Zippe CEO of Zippe with his son Dr Philipp Zippe
Managing Partner and COO of the company
Glass International March 2016
Zippe company profileindd 1 31116 926 AM
Supplier profile Zippe
Glass International March 2016
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many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
bull Scraper conveyors bull Cullet crushers bull Thermal shock test systems
COLD-END COATING
HOT-END COATING
ANNEALING LEHRS
Belt Cleaning Brush
2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
distributors are offered with guarantees covering temperature stability thermal homogeneity and
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
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step in
With more than 40 yearsrsquo experience in automation
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drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
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PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
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Machine challenging
Mould changes Samplings
Laboratory Mould
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Supplier profile Zippe
Glass International March 2016
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many people who have been been with us for 30 years all their working career and so they have a lot of experience We work together like a big family they know my ancestors we know fathers and sons of theirs and thatrsquos a very nice community
The core values are also affected in that we look more for the long-term perspective and not for short-term profit The negative is that maybe we look too little for short-term profit We perhaps take orders that we should rejecthellip ldquoNo not for this time not for this amount of moneyrdquohellip But the positive side outweighs this and when the family works well together with all our employees and our managers it is a very positive situation
How many plantsoffices do you have around the world We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany where we mostly produce conveying equipment We also have representatives in 55 countries all around the world so all the major markets are covered Thatrsquos very helpful because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions Then we have a couple of firmly established companies such as in Italy China England or Poland which help to execute contracts on a larger scale when you have to include local services
Where is the majority of Zippersquos busi-ness done in the world at the momentIt is always changing It changes from year to year At the moment the biggest orders we have are from Europe Latin America and North america these are the biggest jobs that we execute But that can change in a year easily South East Asia always remains an important market for us
Thatrsquos good for Europe ndash often you hear about the market slowing downYes there is still investment in Europe Europe is more of a mature market thatrsquos true so there is not as much growth But still companies are changing locations are changing situations are changing The glass industry is where the market is where the energy is where the raw materials are and so locations even change within Europe from time to time Some factories are closing because they are old and not working efficiently anymore some new ones are being built quite often close to the customer where you have little transport ndash so there is always something going on New types of glass industry are also being developed such as fibreglass and pharmaceutical glass which were maybe not produced on the same scale 20 years ago
Where in the world do you see the most opportunity for future business Asia is still an important market and the Americas and Europe continue to be important In the medium term the clear answer is Africa this will be a market of the future Several countries are coming up very rapidly on the African continent
There is a very simple rule in business that I have experienced over the decades wherever there is stability there is investment Itrsquos very simple Where there is no stability there is no investment You can follow that pattern all over the world Luckily in spite of all the difficulties that are happening in the world and the Middle East and a few countries in North Africa there are still countries in the world with a lot of stability and thus there will be investment Not to forget Iran - there will be a lot of demand for new techniques in this country after years of isolation We are ready to serve this new market
How important is the German market to Zippe The German market is important to us as we usually have a very constant rate of 15-20 of our turnover coming from customers in Germany That means we have an export rate of 80-85 of business outside of Germany Germany has a very dynamic glass industry with many glass factories and is a strong home market which is certainly an advantage for us There wonrsquot be new glass factories built every year not even every three years but there is still always some investment going on
Continuedgtgt
z Zippersquos headquarters in
Wertheim Germany
Zippe company profileindd 2 31116 926 AM
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
bull Belt and spindles tempering lines bull Decorating lehrs bull Chemical tempering ovens bull Roller annealing lehrs bull Mold pre-heating kilns bull Stackers + cross conveyors
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2015 anuncio HALF PAGE ARCA TSF HOT bleed off 3mm CMYK v4indd 1 24042015 161042
VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
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competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Messages Notes
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Laboratory Mould
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
All in one
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Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
Supplier profi le Zippe
Glass International March 2016
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Are you currently developing any new technologies or investing in any RampD efforts that you can tell us about I canrsquot tell you all the details but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly Last year we successfully incorporated and started up at Nampak the fi rst cullet pre-heater that was built overseas and not in Europe and this gives us hope and confi dence for similar cases
Our latest generation of batch chargers the Vibrotube is having a lot of success and so we will continue to develop this system in the future It combines all the advantages of previous chargers without the disadvantages which is to say the screws The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time and the Vibrotube doesnrsquot have that That is another example of sound development
Also user-friendly and more advanced control systems with more management information capabilities ndash this is another area that we are strongly focused on
In your view what are the most press-ing challenges and opportunities fac-ing the glass industry at the moment Itrsquos always the same glass has a certain weight and glass breaks These are the two disadvantages the comparatively heavy weight and the ability to break Everything else speaks for glass ndash there is no other disadvantage It is probably not more expensive than other packaging materials it does not react with any of its contents which is a fantastic ability especially in food packaging and its transparency is great
Energy consumption is also a big factor so cullet-handling systems need to be more advanced in the future These are the biggest challenges
You are President of the VDMA which of course supports glasstec What is it about the show that makes it so impor-tant to the glass industry
First of all it is by far the largest glass show in the world It has a variety of exhibitors and the glass industry itself showcases its products there especially in terms of fl at glass It also has a broad range of technology suppliers to the glass industry which is equally important All the key technology suppliers are at glasstec with large booths that show real machinery ndash at least partly We cannot build a batch house at glasstec it would be larger than one of the halls
Ultimately itrsquos a great place to come together and itrsquos conveniently located It is fi rmly established in peoplersquos minds ndash people are in the habit of going there every two years at around the same time There are other events organised around it such as conferences but the main thing is that you have all the big exhibitors there Every glass person should be there for two days every two years Thatrsquos how we see it
What does your role as President of the VDMA entail in general Do your duties increase in a glasstec year I have been President of the VDMA for six years now and the role entitles you to be the head of the organising committee on the board of glasstec During a glasstec year there is a lot more work than in normal years because you have to prepare meetings and make decisions such as how the opening events will look Of course Messe Dusseldorf prepares all of this very professionally but they also need the advice and the assistance of the board Itrsquos a great role and Irsquom happy to fulfi l it Itrsquos very demanding and very challenging but you always grow with your challenge
Zippe Wertheim Germanywwwzippede
ldquoNot to forget
Iran - there will
be a lot of
demand for new
techniques in
this country
after years of
isolationrdquo
A Zippe batch plant
at SGD in France which
began operation at the end
of 2015
z Zippersquos Vibrotube batch charger
Zippe company profileindd 3 31116 926 AM
Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
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VDVindd 1 3916 245 PM
History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
or obsolete interfaces can seriously impact your
competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
ww
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
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Inspection
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
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Lubrication
Glass International March 2016
Swabbing Robot lubricant success
The hollow glass market has to catch up on new technologies to achieve a higher effi ciency and reach customersrsquo expectations A lot of innovation has already taken place
but there is still a lot to do In this context a huge contrast exists highly automated IS machines are usually still operated with manual swabbing to lubricate the moulds
Belgian company Socabelec known in the glass industry for turnkey automated production lines developed an automatic spray system for Heye International The spray system effi ciently replaces the manual operation of swabbing the blank moulds
However it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants the Glassline SwabMatic 180
Based on their respective know-how in the glass industry the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results zero rejects from swabbing no need for section stops a 75 saving on lubrication consumption and improved operator safety
Recent on-site testing on a Heye IS machine ndash NNPB processlight bottles has proven these results and the glass plant was happy to see a higher production output within the specifi cations
ChallengesBeside the automation approach it was challenging for VDV LubricantsndashGlassline to develop the appropriate lubricant The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company have contributed to a successful conclusion to the project
Lubricating the blank mould is a specifi c process and requires the following criteria a good friction coeffi cient between glass and mould stable in time and something non-polluting and safe for the operator An additional requirement for automatic swabbing was to have a formulation able to be effi ciently sprayed on the blank mould surface Glassline SwabMatic is formulated with a combination of oils solids and additives
VDV Lubricants and Glassline will now in partnership with Socabelec further update the Glassline SwabMatic accordingly to other types of process such as blowblow pressblow and others
Director VDV LubricantsGlasslineSales amp Technical Manager VDV LubricantsGlasslineBaasrode Belgium francoisbreyevdv-lubcomwwwglasslinebe wwwsocabeleccom
Dirk Jongers and Francois Breye discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process
Contact us vidromecanicavidromecanicacom wwwvidromecanicacom
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History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
or obsolete interfaces can seriously impact your
competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
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Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
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Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
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Lab-precision volume measurement at the line
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
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History
Glass International March 2016
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Last year the ovenware product Pyrex celebrated its centenary and Coca Colarsquos iconic bottle was first patented
in 1915 The same year Wes Turner began a mission to revolutionise the UK Glass Industry which led to the formation of the Society of Glass Technology (SGT)
Wes Turner was born in 1881 in Wednesbury West Midlands to William and Blanche Turner the second of seven and their first son His father a man of strong Christian principles was at various times a railway porter signalman ironworker postman and insurance agent Against the odds including polio at three Turner excelled receiving accolades at school and progressed to higher education in Birmingham a Chemistry BSc in 1898 a Masters degree and the Erhardt research prize
In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield Characteristically his first observation was the lack of order in its chemical stores His organisational skills quickly remedied this He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists even offering evening classes He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914)
World War 1 began in July 1914 Following Turnerrsquos suggestion to his vice-chancellor the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt Inevitably he was appointed secretary WW1 also proved a wake-up call to the UK glass industry which had become moribund relying on secret recipes passed down the generations and unable even to measure furnace temperature The sudden lack of imports from the continent required them to extend their product range particularly in laboratory ware and optical components source raw materials domestically
and adapt their technologies Firms in Rotherham Mexborough and Barnsley were quick to seek help and Turner was quick to respond In May 1915 a report on lsquoThe Glass Industry in Yorkshirersquo proposed that a centre for research and teaching on glass manufacture be created In June the proposal became a reality led by Turner The Department of Glass Manufacture soon became the Department of Glass Technology the first in the world
Unusually it was administered by a lsquoGlass Research Delegacyrsquo with members from both the university and industry not by the University Council
The freedom this gave Turner meant he was not always popular with his academic colleagues but lsquothen orthodoxy would have been a serious handicap to a man of Turnerrsquos foresight and drive for innovationrsquo (Douglas) He particularly appreciated the lack of a direct telephone line to the Vice Chancellor
Turner soon strengthened his links to industry by creating lsquothe SGTrsquo which first met formally in November 1916 Wisely the SGT selected its first president from industry Frank Wood of Wood Brothers Barnsley with Turner as secretary Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners Turner perceived that these inward looking firms shared many problems best solved by working collaboratively
The SGT offered a forum for frank discussion of common issues From 1917 it was enhanced by adding a library an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology Early issues remain an amazingly rich source of knowledge both the physical chemistry of making glass and its properties The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (wwwsgtorg)
After the war Turner with almost missionary zeal began contacting international glass experts In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany and others in the USA France Belgium Italy and Spain Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG) still active and represented in 33 countries (wwwicglassorg)
During these visits Turner acquired a substantial Glass Art collection often pieces created uniquely for him or experimental samples by eminent artists In 1943 he donated it to the university where it forms the Turner Museum of Glass He also received many awards (eg OBE FRS DSc) and yet more from overseas Even after retiring (1945) he remained active until his death in 1963
By 1955 the university was pursuing fundamental research alongside industrial trouble shooting and this entailed different funding streams To solve the associated administrative issues the British Glass Industries Research Association (BGIRA) now Glass Technology Services (GTS) was created and housed in a new building next door In 2003 they moved to Chapeltown Sheffield The SGT now shares the same home Professor Turnerrsquos legacy is enormous and retains an ability to adapt in a changing world Herersquos to the SGTrsquos bicentenary r
BibliographyR W Douglas Biographical Memoirs of Fellows of the Royal Society Vol 10 (Nov 1964) pp 325-355F J Gooding amp E Meigh Glass and WES Turner Published by the SGT 1951
Curator of the Turner Museum of Glass Sheffield University UKwwwturnermuseumgroupshefacukjmparkersheffieldacuk
The SGT 100 not out
Prof John ParkerTurner Museum of Glass and ICG
Historyindd 1 31116 253 PM
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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otim
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
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Lab-precision volume measurement at the line
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
British Glass
Glass International March 2016
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AllGlass Scotland produces more than 15000 tonnes of glass beads annually for a host of applications
including refl ective highway paint blast media and water fi ltration
However the process creates huge quantities of residual glass powder This can theoretically be used in bricks concrete fi llers and tiles but all these uses demand a specifi c powder size and grading fi ne powder isnrsquot economically viable for these markets Nor is it easy In fact this powder clogs and wears out machinery ndash and with much of it below 100 microns anyone exposed to it needs to consider PPE
Therersquos no chemical reason it canrsquot be re-melted but again the handling properties are poor The powder can fl oat up rather than dropping into the melt and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage fi lters
So despite its potential value this glass usually ends up in landfi ll Geoff Crutchley at AllGlass has been working on ways to use it ldquoIf we could just fi nd a way to handle it mechanically this could become cullet for re-melt reducing CO2 emissions dependence on raw materials and energy userdquo
It is not hard to understand the impetus each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials)
Pelletised cullet has the potential to further improve energy savings ndash previous studies have suggested that up to 15 less
energy is needed to produce glass from pelletised materials
ldquoOur approach was to form the powder into pellets of around 1cm diameter making it easier to handle store and transport We started on our own lab bench ndash mixing the powder with liquid and a binding agent pressing it into pellets and then drying itrdquo Geoff recalled
ldquoThe Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up automaterdquo
Having previously worked on pelletisation research GTS brought experience of extrusion injection and pan pelletisation along with its analytical and melting facilities This allowed the technique and recipe to be refi ned ndash reaching the optimum point for pellet quality production speed and quantity of binding agent needed
ldquoToo much binding agent pushes the cost right up too little and the pellets disintegraterdquo Geoff explained ldquoBut with GTSrsquos expertise we arrived at a recipe and process that means we can effi ciently produce pellets with a decent crush strengthrdquo
Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace
ldquoWersquod done enough trials with our test furnace to be certain the pellets wouldnrsquot cause any problemsrdquo said Chris Holcroft who leads the GTS team
ldquoBut itrsquos still a big ask to put them through a commercial furnace worth tens of millions of pounds We were incredibly grateful for Alliedrsquos faith in the project The pellets of course did us proud there
was no disruption to the process or the product qualityrdquo
ldquoWe expect that the pellets can be produced at a cost thatrsquos comparable to the price of culletrdquo said Geoff ldquoSo given that we could create several tonnes of these pellets every day from our residual powder thatrsquos a signifi cant potential carbon saving for a glass manufacturer The next step for us is to confi rm the machinery capacities quoted for full-scale production and line up customersrdquo
Chris explained how GTS is keen to explore wider use of pelletisation
ldquoCullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so diffi cult to screen for non-melting contaminants such as ceramics Anything less than 10mm tends to go to aggregate use ndash or landfi ll
ldquoBut milling the cullet to less than 1mm so contaminants do melt is a plausible solution if the glass powder can be pelletised effectively and economicallyrdquo
GTS is also investigating the potential for combining fi lter dust and other fi ne raw materials with the cullet in pellets to improve the handling of these materials
ldquoThat could make thousands of tonnes more glass available for re-melt every year ndash which would be a step towards the glass industryrsquos decarbonisation goalsrdquo Chris said Glass Technology Services Sheffi eld UKenquiriesglass-tscomwwwglass-tscomAllGlass Renfrewshire Scotland UK wwwallglassuknet Zero Waste Scotlandwwwzerowastescotlandorguk
Glass Technology Services
When yoursquore measuring cullet in millimetres or microns itrsquos too small to be recycled right Thatrsquos been common wisdom until now However a partnership between AllGlass and Glass Technology Services funded by Zero Waste Scotland has come up with a more environmentally and fi nancially friendly answer
Small is useful
AllGlass and GTS created pellets that have been
successfully tested in a commercial furnace
The glass on the left was made using normal
batch materials the glass on the right from pellets
British Glassindd 1 31116 1152 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
or obsolete interfaces can seriously impact your
competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
drive solutions we have the know-how to refurbish
any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
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Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
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Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
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Inspection
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Laboratory Mould
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
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嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
All in one
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A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
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53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce 6 Tel +39 0577 304730 ifvfonderievaldelsanecom wwwfonderievaldelsanecom
Case study Verallia Bad Wurzach
Glass International March 2016
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32
Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
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competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
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any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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42
simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Special rules apply to the industrial production of packaging glass because the quantities required are high and the production sites
must keep up with demand The process does not allow for any downtime so the systems are in operation 247 all year long
The compressed air and vacuum supply is also subject to extremely high requirements Numerous compressors and vacuum pumps are installed in Veralliarsquos plant at Bad Wurzach Germany They work in three networks 4 bar 6 bar and a vacuum network as is typical in hollow glass production
The compressors and pumps generate compressed air and vacuum for the production of around 25 million bottles per day The start of the process involves several sumps which each store around 300 tonnes of molten glass at a tempera-ture of approximately 1600oC ndash and they do so 247 During production itself precisely proportioned red-hot glass droplets are lsquoshotrsquo through glass channels to create hollow glass every second In doing so the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig 1)
The compressors in the extensive compressed air station look very different due to their year of manufacture rather than their brand in Bad Wurzach Wittig rotary vane compressors were installed more than 50 years ago The oldest system which is still in operation dates to 1965 It has been in operation for 50 years and is still used as a redundancy machine (Fig 2)
The rotary vane principle This explains the commitment to the principle of the rotary vane compressor which was patented in 1908 by Karl Wittig Wittig was the first company to apply the multi-cell principle A rotor is mounted eccentrically in a cylindrical housing
The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes Gas and centrifugal forces press the rotor vanes against the wall of the housing enabling air or gas to be taken in compressed and discharged
The low speed of 1500 rpm the low rotor weight
and the low amount of
moving parts all help to ensure a long
service life with minimal maintenance requirements
As a result rotary vane com-pressors are extremely durable even when used 247 as evidenced by the 50-year-old machine at the Verallia plant
The rotary vane compressors with performance ranges of 250 to 6000msup3h or 30 to 710kW are developed and produced at Gardner Denver in Schopfheim
The energy-conscious user Energy efficiency is important at all of Veralliarsquos production sites In particular this also applies to compressed air and vacuum generation which makes up a considerable proportion of the energy consumption of the plant
Siegfried Heinrich Head of the mechanical maintenance department responsible for compressed air supply at Bad Wurzach said ldquoThe compressed air network requires around 55000 - 60000kWh of electrical energy per day while vacuum generation requires less than 15000kWhrdquo
To generate the required amounts of air economically all newer compressors are equipped with regulated speed drives
The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC
z Fig 2 Several rotary vane
compressors dating back to
between 1965 and 1975 are in
use at Verallia Deutschland
case study garden denverindd 1 31016 919 AM
Case study Verallia Bad Wurzach
Glass International March 2016
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Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Case study Verallia Bad Wurzach
Glass International March 2016
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33
Verallia installs synchronous reluctance
Continuedgtgt
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig they also make excellent partners when it comes to the further development of the machines
Verallia has consistently provided Gardner Denver with suggestions for improvement which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custom-built Produced in Schopfheim with a high degree of vertical integration the production paths are kept short
For example the sound hood was optimised at Veralliarsquos request so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair
Implementing the drive technologyThe newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig 3) which supplies up to 1408m3h of compressed air into the 4 bar network The ROW compressors are standard compressors in many operations that require continuous compressed air They are equipped with three-phase asynchronous motors and frequency converters from ABB
After Verallia ordered the ROW 170 ABB approached Gardner Denver with a new drive concept At that point the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start produc-tion They are ranked in efficiency class IE4 and can be used together with conventional ABB converters
When launching such innovations all system manufacturers are faced with the same dilemma many users want to use energy-saving technology but nobody wants to be the lsquoguinea pigrsquo particularly when there are no practical comparative values available and the benefit is not clear
So a collective idea arose a new energy-saving drive concept for rotary vane compressors was available As was a manufacturer of compressors that wanted to use the concept along with a highly active and critical user Why not come together to carry out a practical test that would
benefit all involvedThe idea became a reality The operating
parameters of the new compressor at Verallia (with the lsquooldrsquo drive) were precisely recorded over several months They then switched to the synchronous reluctance motor and continued the measurements (Fig 4)
The result is a comparison of both drive systems under identical conditions And in theory it is better than they had hoped Henrik Braumlutigam ABB Automation Products stated ldquoThe calculations indicated a 08 advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor This is the value specified in our documents However the measurements showed that the efficiency was improved by 15rdquo
Advantages The reduced energy consumption is not the only advantage of the new drive Mr Braumlutigam stated ldquoThere is no slip during operation in the synchronous machine This means that the motor and thereby the entire machine runs more quietly The rotor does not produce any losses and less waste heat is generated When it comes to compressors this is an important factor because heat promotes bearing wear As a result we also expect that the maintenance intervals of the compressor bearings will be increasedrdquo
Furthermore the motor only runs under partial load with 80 to 85 of the full load This is where the degree of efficiency of the reluctance motor is at its best ndash and therefore the wear is low as the motor is never run at its performance limits
Another major advantage of the synchronous reluctance motors is their compact design the fitters at Verallia in Bad Wurzach were able to replace the drives 11 as the new drive fitted in the existing sound hood This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines which are still equipped with IE1 and IE2 motors to benefit from increased efficiency and
technology
Veralliarsquos Bad Wurzach plant was the first to test drive technology for Gardner Denverrsquos ro-tary vane compressors from the Wittig brand Bernd Haas reports on the results obtained which demonstrated an increased efficiency and lower energy consumption compared to previous machines
Fig 1 A look at glass production at Verallia
z Fig 3 The first Wittig
rotary vane synchronous
reluctance motor with an IE4
efficiency class
case study garden denverindd 2 31016 919 AM
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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fuel consumption
Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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37
Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
An IS machine keeps going almost indefi nitely ndash
provided the control system doesnrsquot let you down
fi rst In practice however discontinued products
or obsolete interfaces can seriously impact your
competitiveness ahead of time This is where we
step in
With more than 40 yearsrsquo experience in automation
FMT24S distributed control systems and FDU24S
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any IS machine in the market Now and in the future
YOUR PRODUCTION HAS A GREAT FUTURE
2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
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Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
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Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
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Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
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Lab-precision volume measurement at the line
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Laboratory Mould
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Case study Verallia Bad Wurzach
Glass International March 2016
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35
retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
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the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
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futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
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2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
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Messages Notes
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Laboratory Mould
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Case study Verallia Bad Wurzach
Glass International March 2016
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retrofi t a reluctance motor Even the control technology poses no problems a new programme simply needs to be installed onto the existing ABB converter (Fig 5)
Conclusion The comparative test was conclusive for ABB and Gardner Denver with a payback period of much less than two years the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor
The test also impressed those responsible at Verallia (Fig 6) They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim Needless to say it is equipped with an IE4 synchronous reluctance motor from ABB
z Fig 4 The drive was replaced 11 because it requires no more space than a
regulated speed asynchronous motor
z Fig 5 The existing converter (left)
is still used and simply required new
software
z Fig 6 The stars of the comparative test from left to right Bernd Haas Man-
ager Sales Systems of Gardner Denver Schopfheim Siegfried Heinrich Head of
the mechanical maintenance department at Verallia Deutschland and Henrik
Braumlutigam ABB Automation Products
Bernd HaasManager Sales Systems Gardner DenverSchopfheim Germanywwwgardnerdenvercom
Verallia Bad Wurzach Germanywwwveralliacom
PSR System 500Forehearths
and Distributors
GUARANTEEDperformance where
the glassmakerneeds it most
Subject to technical specification terms and conditions System 500 forehearths and
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Are yours
ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS
PARKINSON-SPENCER REFRACTORIES LTDHolmfield Halifax West Yorkshire UK HX3 6SX
Tel (44) (0) 1422 254472 bull Fax (44) (0) 1422 254473Email adminparkinson-spencercouk bull wwwparkinson-spencercouk
case study garden denverindd 3 31016 920 AM
Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
GLASS HAS A GREAT PAST
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
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Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
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Lab-precision volume measurement at the line
Multi-line support
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Production
Messages Notes
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Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
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倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Melting | Forming | Automation | Energy
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Refractories
Glass International March 2016
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Recycling refractoriesMike OrsquoDriscoll discusses how the recycling of refractories is entering a new era with the rise of secondary raw materials becoming a dominant factor
The recycling of refractories has been around for at least three decades although it has only been in the last
few years that the sector has witnessed increased commercial activity
The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers which include refractory users such as steel non-ferrous metal cement and glass plants
This trend not only helps to find a much needed environmentally-friendly solution for spent refractories but also helps to conserve mineral resources energy consumption and the overall cost of refractory production as well as minimising the expense of landfill costs for end users
The movement has received an additional boost from the development of relevant processing and quality control techniques such as Laser Induced Breakdown Spectroscopy (LIBS) and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives
The upshot is that waste refractories will be just one of a range of secondary raw material resourcesndash along with for example steel slag fly ash waste water glass paper plasterboard and red mud ndash from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade The era of secondary raw material (SRM) supply is upon us (Fig 1)
The industrial minerals marketIn spite of declining specific refractory consumption (10-15kgt steel 3kgt non-ferrous metal 1kgt cement 4kgt glass) around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide
Continuedgtgt
Circle of refractory life Refractory recycling in simplified stages
Sourcerefractory
waste from end user eg alerted
to break-outOn-site
assessment and price negotiation of spent refractories
Extract spent refractories and
transfer to processing plant
Initial crushing of shapes to 200-
400mm sizes
Packed stored ready for sale to refractory
manufacturer (or other end user)
Refractory product manufactured and sold to end user
Crushed dried screened iron
removal Using hand orautomated sensor technology sort by
chemical composition fines unrecyclable waste composition
analysed segregation Fig 1 Circle of refractory life
That equates to a lot of mineral deposit exploration development mining processing and trading by mineral suppliers and a lot of sourcing buying and logistics activity by refractory raw material purchasers
Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals consuming as many as 24 different industrial minerals
Certain key refractory minerals such as andalusite bauxite fused alumina graphite dead burned and fused magnesia silicon carbide and zircon have experienced and continue to experience supply chain issues
These issues include Limited development of commercial scale resources overreliance on leading sources which have local issues that impact supply (China in particular which is responsible for 40-90 of refractory mineral supply to global users) inconsistent quality and supply availability and pricing and logistics issues Such factors are a nightmare for refractory raw material purchasers (Fig 2)
Refractory mineral purchasers are therefore seeking alternative raw material sources With the rapidly evolving
refractories recycling sector it will soon become the lsquonew normalrsquo for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options Primary and secondary raw materials (SRM)
While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing it is clear that in recent years these challenges have been increasingly met
Certain mineral processing companies have now developed a niche in mineral recycling and in particular processing refractory minerals from spent refractories
Such companies include DEREF Italy Harsco Metals amp Minerals UK REF Minerals Latvia Refra-System Hungary TYMO Engineering Germany Valoref France LKAB Minerals UK Mineralen Kolleacutee Netherlands Horn Germany
This is expected to be a growing trend with more players emerging in the near future There is also likely to be more
IMMFindd 1 31116 1252 PM
Refractories
Glass International March 2016
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attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
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2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
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Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
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otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
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Lab-precision volume measurement at the line
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Refractories
Glass International March 2016
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38
attention given to recycling refractories by the leading refractory manufacturers and end users
Future use of SRMsSteel producers are already turning their attention to refractory recycling For example Italyrsquos Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag However it remains a case of lsquoearly daysrsquo
In his UNITECR 2015 presentation Melvyn Bradley Technical Director of LKAB Minerals UK acknowledged that despite LKABrsquos involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories) ldquoCustomer feedback has highlighted the need to improve the quality of the recycled refractory material meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished productrdquo
In general refractory SRM now appear to be more widely accepted in the refractories industry than previously Europe is ahead of the pack globally although Asia and North America are starting to pick up the baton
Precise figures for refractory SRM or refractory lsquorecyclatersquo are hard to ascertain and published figures vary
Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements but where price remains a significant factor
Typical waste refractories that can be recycled include firebrick mid-alumina brick bauxite brick alumina-carbon alumina-magnesia and magnesia-carbon bricks
While the use of recycled aggregate in mag-carbon bricks is now common practice according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks
Typical applications for alumino-silicate SRM include medium range castables and precast shapes Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products
Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment and mag-carbon SRM used as a slag conditioner in EAF
In addition to providing SRM for refractory manufacture spent refractories can become raw materials for powder coating applications metallurgical additives slag conditioners and feedstock for cement
Refractory recycling outlookThere is no doubt that refractory recycling is going to see an increase in attention and activity Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
z Fig 2 Refractory mineral summary table
Refractory Industrial mineral Main chemical Primary source
classification (incl synthetic) component country
BASIC Dead burned magnesia 85-998 MgO China
Fused nagnesia 97-998 MgO China
Dead burned dolomite 56-62 MgO 36-40 CaO USA
Chromite gt46 Cr2O3 South Africa
Sinteredfused spinel 66-80 Al2O3 21-33 MgO China
Olivine 40-50 MgO 34-45 SiO2 Norway
ACIDIC Calcined alumina gt995 Al2O3 China
High alumina Fused alumina 94-995 Al2O3 China
Calcined bauxite 85-88 Al2O3 China
Sinteredfused mullite 40-75 Al2O3 USA
Low alumina Andalusite sillimanite kyanite 60-65 Al2O3 South Africa
Refractory clays 20-45 Al2O3 China
Pyrophyllite 20-30 Al2O3 South Korea
Silica Quartzite silica sand gt97 SiO2 Regional
Fused silica gt998 SiO2 USA
SPECIALISED Zircon 66 ZrO2+HfO2 Australia
Zirconia gt99 ZrO2 China
Silicon carbide gt93 SiC China
Graphite 75-99 C China
INSULATING Diatomite gt75 SiO2 USA
Perlite 65-80 SiO2 China
Vermiculite 45 SiO2 South Africa
their own recycling plants it is expected that an increasing number of refractory recycling processors will enter the market in the near future
Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing recycling processingsorting equipment supply logistics marketing and purchasing
Key trends to monitorr More and improved automation
systems particularly in refractory waste sorting
r Development of mobile sorting systems
r Research in refractory additives such as microsilica to improve the performance of products based on refractory SRM
r Development of pelletisation of refractory SRM fines for use in other applications such as slag conditioning
r Development of new refractory formulations to enhanceease their successful recyclability
r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users) refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM
r Education of refractory end users (eg steel producers) to positively engage in and recognise the benefits of refractory recycling including reasonable prices for the sale of refractory waste
r Clarification and universal (eg EU) establishment of clear legislation regulations and licences regarding handling processing and trade in refractory waste and refractory SRM r
IMFORMED is organising the Mineral Recycling Forum 2016 14-15 March 2016 Rotterdam focusing on the SRM supply chain including refractories and MagForum 2016 9-11 May 2016 Vienna focusing on magnesia supply and de-mand including refractories
Mike OrsquoDriscoll Director IMFORMED Industrial Mineral Forums amp Research LtdMarket research and specialist conferenc-es for the industrial minerals business mikeimformedwwwimformedcom
IMMFindd 2 31116 1252 PM
automation in a new dimension
futronic GmbH middot Tolnauer Strasse 3-4 middot 88069 Tettnang (Germany)Tel +49 7542 5307-0 middot Fax +49 7542 5307-70 middot infofutronicde
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2015-4500-005_FUT_Anzeige_Glas_ENindd 1 270116 1712
Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
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Lab-precision volume measurement at the line
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挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
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Lab-precision volume measurement at the line
Multi-line support
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Refractories
Glass International March 2016
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Analysis of glass defect compositions from AZS refractory
A fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass
industry It has a remarkable resistance to corrosion in the glass melt and glass melting environment
Determining the originDespite its advantages the presence of the glassy phase in the AZS refractory is a problem While there can be many sources of cord defects refractory contamination in glass is frequently cited as a leading source Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories
The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
part of the glassy phase at the surface of the refractory The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material When this boundary layer ends up in the bulk of the melt it forms a knot or a cord
To eliminate a cord defect problem in industrial glass production an indication of the origin of the cord in the furnace is helpful
The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production To identify a potential source of inhomogeneities the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1 2]
Glass defect databaseA database of 69 chemical compositions of defects mainly cords has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months
These products were collected due to the observation of high defect presence in daily production The products came from different furnaces in which glass melt with the same glass composition was prepared The composition of glass defects in wt analysed by EDX analysis on a commercial basis by Glass Service Czech Republic are in Table 1
These compositions are ordered from the highest to the lowest value of the
Peter Šimurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production
Continuedgtgt
35
30
25
20
15
10
5
0
0 5 10 15 20
Number
wt
()
Al2O3
Al2O3
25 35 4030
35
30
25
20
15
10
5
0
0 10 20 30 40Number
wt
()
Al2O3 K2O
Al2O3 Al2O3(glass)
50 70 8060
K2O K2O (glass)
Fig 1 Content of Al2O3 and K2O in glass defects ordered from the highest to the
lowest value of Al2O3 (wt )
Fig 2 The content of Al2O3 in glass defects ordered from the highest to the
lowest value Al2O3 gt50 (wt )
Simurkaindd 1 31116 1253 PM
Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
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Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
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Inspection
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
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Lab-precision volume measurement at the line
Multi-line support
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Laboratory Mould
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
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Refractories
Glass International March 2016
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41Continuedgtgt
Al2O3 content The composition of glass surrounded glass defects which is presented in Table 1 (Glass) was determined as the average value from an analysis of 30 samples
The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample
Results The detailed analysis of the individual oxide content in the glass defects presented in[1] revealed that there are pairs of cords with comparable chemical composition they differ mainly by the presence of ZrO2 (Table 1 eg No 18amp20 25amp26 44amp45)
As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other we can say that these cords originate from the same kind of source
A cord originating from the AZS refractory glassy phase may not contain ZrO2 the content of other oxides mainly K2O plays an important role in determining the cord origin
Fig 1 shows the Al2O3 and K2O content in glass defects ordered from the highest value to the lowest value of Al2O3
The red line represents the level of Al2O3 the green line is the content of K2O in the glass surrounding the knots and cords (Glass)
It was shown that there are chemical compositions of the cords (Table 1 defects No 54-69) where the difference of the Al2O3 content is not higher than 05 wt in comparison with its content in the original glass
Simultaneously the content of other oxides is not far from their content there It is possible to say that the origin of these defects is not in the AZS material
Possible reasons for their creation can be incorrect batch weighing andor mixing incorrect granulometry of raw materials unsuitable cullet evaporation of alkali from the glass melt surface and so on
The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
Table 1 Chemical composition of cords glass
surrounded defects and AZS refractory glass phase
(wt )
No Na2O Al2O3 SiO2 K2O C aO ZrO2 BaO
1 1282 3215 4744 562 078 083 036
2 847 303 4990 998 029 055 079
3 1075 2533 5210 799 096 18 182
4 1120 252 5193 773 14 150 159
5 1078 2311 5432 759 155 083 181
6 1077 2267 5380 764 160 173 181
7 957 2266 5541 796 212 059 181
8 1083 228 5359 718 286 100 2
9 1048 1770 6177 714 143 147
10 870 1656 6300 823 194 157
11 873 1639 6313 785 25 185
12 966 1619 6229 755 229 23
13 849 1574 6405 776 216 181
14 1000 1560 5867 548 624 129 272
15 868 1532 6492 767 178 015 150
16 937 151 6337 763 157 12 25
17 848 1459 6550 780 211 007 157
18 947 1456 6307 761 190 232 15
19 899 1431 6229 660 441 125 214
20 950 1423 6446 748 214 220
21 964 1391 6166 747 388 12 243
22 840 1380 6542 794 261 183
23 1032 1361 5696 897 328 380 37
24 961 1341 6371 772 283 077 194
25 91 1319 6600 764 22 214
26 954 1273 6531 74 212 082 247
27 968 1257 6073 686 273 515 229
28 824 1254 6589 781 321 230
29 988 1213 6449 699 259 192 200
30 958 1186 6392 745 274 256 189
31 899 118 6747 680 320 023 225
32 888 1167 6570 716 385 043 231
33 993 1126 6604 682 316 053 226
34 100 106 658 66 23 26 22
35 948 106 6653 6915 252 227 223
36 897 104 6354 686 346 444 269
37 855 993 6784 733 395 24
38 867 974 6709 681 438 047 283
39 105 942 6642 684 38 262 156
40 999 932 6218 612 320 64 313
41 999 923 6511 644 554 059 310
42 932 919 6777 73 297 19 263
43 88 888 6802 728 419 080 276
44 983 689 6927 667 492 242
45 984 673 6903 626 459 093 263
46 1048 655 6511 564 469 378 371
47 1064 550 6847 577 585 049 328
48 1112 500 7064 540 477 000 345
49 1093 442 6930 562 594 083 296
50 1014 400 7042 597 527 000 419
51 1036 317 6961 560 681 050 396
52 1046 272 6967 531 731 059 394
53 763 242 7264 531 752 000 447
54 1051 170 7391 520 553 000 377
55 1012 170 7435 523 526 000 396
56 1064 168 7298 522 553 000 395
57 910 159 7162 547 830 021 372
58 1076 157 6986 527 794 017 442
59 1010 150 7533 518 481 000 352
60 1054 147 7073 550 780 000 442
61 1022 145 7310 532 569 000 422
62 1017 121 7187 520 753 000 410
63 1026 117 7143 516 763 000 434
64 973 113 7400 552 547 000 417
65 1000 120 7427 539 555 000 379
66 952 100 7530 526 525 000 368
67 929 097 7544 537 512 000 382
68 1032 085 7159 530 772 000 423
69 918 079 7338 543 730 000 474
Glass 106 12 715 53 71 00 44
AZS glass 26 176 770 0 05 11 0
phase
Simurkaindd 2 31116 1253 PM
Refractories
Glass International March 2016
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42
simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
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Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
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Laboratory Mould
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倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
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吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
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studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
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A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
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Refractories
Glass International March 2016
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simultaneously higher content of K2O in comparison with their content in bulk glass
Fig 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 gt50 (wt ) where four groups of defects are identified
ndash content of Al2O3 303 - 322 228 - 253 89 ndash 177 and 55 ndash 69
The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt while the content of Al2O3 is about 22-25 in the part below the metal line There was no boundary layer observed
Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere which causes dissolution of the AZS crystalline alumina phase
In many cases most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]
When we look at the composition of glass defects No 1 and No 2 we can see that there is content of Al2O3 higher than 30 wt and they are enriched by alkali oxides (1282 of Na2O ndash No 1 and 998 K2O ndash No 2) These facts indicate the glass defects originate from the AZS refractory ndash a part above the metal line
The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]
Bubbles which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material squeezed a part of the glass phase into the bulk of the glass In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase
The content of Al2O3 in glass defects of the Group 2 (No 3 ndash No 8) is from 228 to 253 wt
Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1]
indicates that these cords came from this
Table 2 Chemical composition of cords collected soon after the beginning of campaign in wt
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO
31st 1093 442 6930 562 594 083 296
32nd 984 673 6903 626 459 093 263
57th 993 1126 6604 682 316 053 226
part of refractoryAnother potential source of defects is
in the saturation boundary layer which is created during the furnace campaign in the glassrefractory interface of the working or melting part of the furnace
The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na K Ca Ba) from the glass melt into the refractory dissolution of the Al2O3 and ZrO2 in the glass phase diffusion of Zr and Al from the refractory into the glass melt creation and erosion of the boundary layer area[2] The figures of created boundary layers are presented in[12]
Bubbles created in the interface squeezed a part of interface layer into the bulk of the glass
Another source of defects is the boundary layer which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass
Table 2 shows the compositions of the glass defects collected in production after the beginning of campaign ndash in the 31st 32nd and 57th days of production
As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects
Originally there was 12 of Al2O3 in the glass melt and 176 of Al2O3 in AZS refractory glass phase
We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt the content of Al2O3 is increasing continuously to 44 67 and 113
ConclusionThe analysis of glass defect compositions originating from AZS refractory during tableware glass production showed
r The cords with the content of Al2O3 about 30 wt come from the part above glass level
r The cords with the content of Al2O3 about 22-25 wt originate from the AZS material from melting part located below the metal line
r The boundary layer of the melting or working part is the source of the other cords
AcknowledgementsThis publication was created in the frame of the project lsquoIndustrial research for reaching more effective melting and forming technology of tableware glassrsquo ITMS code 26220220072 r
References[1] Šimurka P Kraxner J Vraacutebel P Pauco T Corrosion of AZS Refractories ndash Source of Defects in Tableware Glass 13pp Proceedings of the 76th Conference on Glass Problems 2-5 November 2015 Columbus Ceram Eng Sci Proc to be published 2016[2] Šimurka P Kraxner J Vraacutebel P Pauco T Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt 5pp Scientificnet Key Engineering Materials (Trans Tech Publications) to be published 2016[3] Selkregg KR Gupta A Knots Analysis and Minimisation in High-Quality Glasses Ceram Eng Sci Proc 23 (2002) 59[4] Dijk Van FAG Glass Defects Originating from Glass MeltFused Cast AZS Refractory Interaction PhD thesis Eindhoven University of Technology (1994)
Peter Šimurka Joint Glass Centre of the II SAS Trenciacuten Slovakiapsimurkagmailcomwwwsavsk
Simurkaindd 3 31116 1253 PM
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
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hu
We build glass furnaces for you
Inspection
Glass International March 2016
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Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
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skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
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widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
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PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
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Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
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倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
H-9201 Mosonmagyaroacutevaacuter POBox 29 Hungary Tel +36 96 574 100 Fax +36 96 574 235
e-mail fusedcastmotimhu
MOTIM
ww
wm
otim
hu
We build glass furnaces for you
Inspection
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
44
Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
46
A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
available today
PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
CLASSIFIEDS
contact us vidromecanicavidromecanicacom wwwvidromecanicacom
for Tableware and Stemware
TEMPERING LINES ON BELT SPINDLES
ANNEALING amp DECORATING LEHRS for Containers and Tableware
KBA-KAMMANN GmbH Bergkirchener Str 228D-32549 Bad Oeynhausen (Germany)
Fon +49 (0) 5734 5140-0 Fax +49 (0) 5734 5140-5130mailkba-kammanncom wwwkba-kammanncom
DECORATING MACHINES
FLEXIBLEPRECISEINNOVATIVE
Rio Tinto Minerals
2 Eastbourne TerraceLondon W2 6LG UK
Tel +44 (0) 207 781 1450Fax +44 (0) 207 781 1851Email simoncookriotintocomWeb wwwriotintomineralscom
Global CombustionSystems
Total Support
Unit 43 Evans Business Centre Easter Inch Bathgate EH48 2EH Scotland UK
Tel+44 (0) 1506 657310Fax +44 (0) 8704 799975Email SalesglobalcombustioncomWeb wwwglobalcombustioncom
TIAMA ZA des Plattes 1 Chemin des Plattes 69390 Vourles France
Tel +33 (0) 4 37 20 15 00Fax +33 (0) 4 78 07 94 50
Email marketingtiamacomWebsitewwwtiamacom
INDUSTRIAL GAS ENGINEERS U N I T D 2 B RO O KS I D E B U S IN E S S PA R K G RE E NG A TE C H AD D E RT O N M2 4 1 G S EN G L AN D
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INDUSTRIAL GAS ENGINEERS
Unit D2 Brookside Business Park Greengate Chadderton M24 1GS UK
Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812Email salesmontselascouk wwwmontselascouk
MANUFACTURERS AND SUPPLIERS OF SELAS SQUARE PORT GAS amp AIR VALVES
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ANNEALING LEHRS
HOT END WARE HANDLING
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RAW MATERIALS
INSPECTION
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ContactEsme Horn
T+44 (0) 1737 855136to book your space
Low-Emission Oxy-fuel Solutionsbull Oxygen amp oxygen flow control equipmentbull Global oxygen enrichment applicationsbull Cleanfirereg oxy-fuel burnersbull Start-up servicesInerting Applicationsbull Hydrogen nitrogen amp other gasesbull Enabling flow control equipment
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Ware Handling Made EasyComplete intergrated Ware Handling package2 amp 3 Axis Servo StackerAdvanced Lehr Cross ConveyorWare Transfer units for ALL types of productionAdjustable pocket PushbarsWorldwide service and support teamDedicated to resolving your Ware Handling problems
Airfield Business Park Elvington York YO42 4AU UKTel 0044 1904 608999Email salessheppeecomWeb wwwsheppeecom
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Sheppee Classified advertpdf 1 04022016 103415
Graphoidal Developments Ltd Broombank Road Chesterfield
S41 9QJ England
Tel +44 (0) 1246 266000Fax +44 (0) 1246 269269
Email salesgraphoidalcomWebsite wwwgraphoidalcom
Lubricating and Coating Solutions
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CLASSIFIEDSindd 1 31016 957 AM
倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
Inspection
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
44
Improving the quality of hollow glass through inspectionElroy Garza talks us through the latest developments in inspection equipment and software at Iris Inspection Machines including advances that match up to the precise requirements stipulated by luxury glassware producers
Continuedgtgt
The world of hollow glass is moving at a rapid rate Every year there are vital improvements in quality design
processes and inspection all to increase consumer safety The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production
Also consumer safety has become a human right with even developing countries demanding better quality Every year new non-government organisations that defend consumer safety are created in developing countries
Inspection quality and standards which verify the safety of each produced bottle have evolved at the same rate as the market itself The market is evolving rapidly in terms of bottle shape colour size design and complexity of the logo Today the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects literally lsquozoomingrsquo to detect even smaller defects
These improvements include modern optical capacities which allow inspection and analysis of each bottle at a 360deg angle in high resolution The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep and the Multi-Model software allows the Evolution machine to inspect up to seven different articles at the same time (Fig1)
The Selector software detects bottle deformation height and several other dimensions and many other developments that Irisrsquo RampD department is working on (Fig2) It accurately inspects all kinds of critical and non-critical defects while giving glassmakers
extra plant efficiencyApart from unveiling important
hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines Iris has also developed equipment that addresses the precise requirements of luxury glassware producers requiring the highest levels of perfection
The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact camera-based inspection machines
Transparent inspectionEvolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complex-shaped articles required for perfumery cosmetics premium liquor and luxury applications as well as high quality tableware
Typical defects detected include loading and compression marks transparent surface blisters cat scratches orange peel
cold mould laps and tears and wash boards (Fig3)
Despite the advances made in non-contact glass container inspection technology in recent years existing machines have been unable to provide the quality of transparent defect inspection required by the glass industryrsquos high-end producers
As part of an ongoing research and development programme the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants
One of Francersquos leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept This provides an automated on-line inspection solution compared to previous
z Fig1 Multi-Model inspection screen on the Evolution 12 with 6 different articles (height shape size etc)
on the same line
Irisindd 1 31016 933 AM
Inspection
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
46
A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
available today
PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
CLASSIFIEDS
contact us vidromecanicavidromecanicacom wwwvidromecanicacom
for Tableware and Stemware
TEMPERING LINES ON BELT SPINDLES
ANNEALING amp DECORATING LEHRS for Containers and Tableware
KBA-KAMMANN GmbH Bergkirchener Str 228D-32549 Bad Oeynhausen (Germany)
Fon +49 (0) 5734 5140-0 Fax +49 (0) 5734 5140-5130mailkba-kammanncom wwwkba-kammanncom
DECORATING MACHINES
FLEXIBLEPRECISEINNOVATIVE
Rio Tinto Minerals
2 Eastbourne TerraceLondon W2 6LG UK
Tel +44 (0) 207 781 1450Fax +44 (0) 207 781 1851Email simoncookriotintocomWeb wwwriotintomineralscom
Global CombustionSystems
Total Support
Unit 43 Evans Business Centre Easter Inch Bathgate EH48 2EH Scotland UK
Tel+44 (0) 1506 657310Fax +44 (0) 8704 799975Email SalesglobalcombustioncomWeb wwwglobalcombustioncom
TIAMA ZA des Plattes 1 Chemin des Plattes 69390 Vourles France
Tel +33 (0) 4 37 20 15 00Fax +33 (0) 4 78 07 94 50
Email marketingtiamacomWebsitewwwtiamacom
INDUSTRIAL GAS ENGINEERS U N I T D 2 B RO O KS I D E B U S IN E S S PA R K G RE E NG A TE C H AD D E RT O N M2 4 1 G S EN G L AN D
T E L E P H ON E 0 1 6 1 - 6 5 4 7 7 0 0 F A X 0 1 6 1 - 6 5 5 3 8 1 2
E-MAIL S A L E S MO N T S E L A S C O U K WWWMONTSELASCOUK
INDUSTRIAL GAS ENGINEERS
Unit D2 Brookside Business Park Greengate Chadderton M24 1GS UK
Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812Email salesmontselascouk wwwmontselascouk
MANUFACTURERS AND SUPPLIERS OF SELAS SQUARE PORT GAS amp AIR VALVES
AIR GAS
ANNEALING LEHRS
HOT END WARE HANDLING
HEAT-UP SERVICES
SCREEN PRINTINGLUBRICATING AND
COATING SOLUTIONS
RAW MATERIALS
INSPECTION
COMBUSTION EQUIPMENTCOMBUSTION
SYSTEMSBURNERS
GLASS LEVELMEASUREMENT
Glassman events visitwwwglassmaneventscom
ContactEsme Horn
T+44 (0) 1737 855136to book your space
Low-Emission Oxy-fuel Solutionsbull Oxygen amp oxygen flow control equipmentbull Global oxygen enrichment applicationsbull Cleanfirereg oxy-fuel burnersbull Start-up servicesInerting Applicationsbull Hydrogen nitrogen amp other gasesbull Enabling flow control equipment
(39101)
800-654-4567 (code 344)gigmrktgairproductscomairproductscomglass
Ware Handling Made EasyComplete intergrated Ware Handling package2 amp 3 Axis Servo StackerAdvanced Lehr Cross ConveyorWare Transfer units for ALL types of productionAdjustable pocket PushbarsWorldwide service and support teamDedicated to resolving your Ware Handling problems
Airfield Business Park Elvington York YO42 4AU UKTel 0044 1904 608999Email salessheppeecomWeb wwwsheppeecom
C
M
Y
CM
MY
CY
CMY
K
Sheppee Classified advertpdf 1 04022016 103415
Graphoidal Developments Ltd Broombank Road Chesterfield
S41 9QJ England
Tel +44 (0) 1246 266000Fax +44 (0) 1246 269269
Email salesgraphoidalcomWebsite wwwgraphoidalcom
Lubricating and Coating Solutions
for the Glass Container Industry
C
M
Y
CM
MY
CY
CMY
K
Classified Ad1pdf 1 03022016 135319
CLASSIFIEDSindd 1 31016 957 AM
倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
Inspection
Glass International March 2016
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-int
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45
skilled but labour-intensive methods This innovation was made possible
by incorporating the latest advances in cameras light source and lens technology combined with intelligent software improvements
Similarly specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries both within the body of a container or externally unless detected before reaching the client
Measurement solutionAlso available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware providing the benefits of unseen precision Evolution Dim equipment provides the advantages of non-contact inspection no rotation and 360deg vision on the production line
Although Evolution 12 incorporates
some aspects of dimensional measurement its performance is not as precise as required by some luxury glassmakers
Evolution Dim has been developed to satisfy these needs more accurately incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well
It is possible to measure accurate article height for example as well as minimum and maximum diameters roundness and barrelling Defects detected include tiny body deformations non-round sidewall diameter deformation or other minor geometrical defects on the body bulged or sunken sidewalls and out-of-specification height
Evolution Dim calculates the verticality of each container to measure the body or finish shifting Defect examples include lean articles offset finish and bent neck
The dedicated finish camera integrates the accurate measurement of minimum
z Fig 2 Internal measurement recognition with
the Selector software
z Fig 3 Low contrast defect (orange skin) detect-
ed with the Evolution Ultimate
z Fig 4 Inspection zone for finish external diameter finish height and finish flatness with Evolution Dim
and maximum finish external diameter finish height height of the finish ring and finish flatness (Fig4)
The machine is equipped with dedicated optics allowing precise measurements The machine is also equipped with HD cameras and an HD screen with a user-friendly interface built for the machine The hardware and software are compatible with other Evolution machines sharing the same spare parts and software
Vision for inspectionThe Evolution range has evolved and has a new PC larger HD touch screen (215in) HD cameras and new software Within its newly designed processing unit Iris has reduced maintenance costs via the new design and assembly employed
There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel Improved cooling is another important feature
The 215in high definition screen provides quicker accessibility to different screens less switching between screens the instant display of parameters faster adjustments quicker optimisation and easier fine-tuning
The screen permits the full display of high-resolution images taken by high-resolution cameras with no need to zoom This provides a realistic view of containers and faults better detection of small faults and an improved understanding of machine behaviour
The high-resolution cameras are 400 more powerful than before providing sharper and more accurate images as well as improved discrimination between different types of defects (eg small stones and blisters) better definition of container shapes and excellent dark glass inspection capabilities The cameras also feature higher dynamics in terms of noise interference thereby improving the quality of the image provided
Iris therefore believes that the Evolution equipment is fast powerful and user-friendly offering enhanced precise inspection of glass containers Retrofit kits are available for all existing Evolution machines r
Area Sales Manager Iris Inspection Machines Bron Francewwwiris-imcom
Irisindd 2 31016 933 AM
Plant technology
Glass International March 2016
ww
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-int
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A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
ww
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47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
available today
PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
CLASSIFIEDS
contact us vidromecanicavidromecanicacom wwwvidromecanicacom
for Tableware and Stemware
TEMPERING LINES ON BELT SPINDLES
ANNEALING amp DECORATING LEHRS for Containers and Tableware
KBA-KAMMANN GmbH Bergkirchener Str 228D-32549 Bad Oeynhausen (Germany)
Fon +49 (0) 5734 5140-0 Fax +49 (0) 5734 5140-5130mailkba-kammanncom wwwkba-kammanncom
DECORATING MACHINES
FLEXIBLEPRECISEINNOVATIVE
Rio Tinto Minerals
2 Eastbourne TerraceLondon W2 6LG UK
Tel +44 (0) 207 781 1450Fax +44 (0) 207 781 1851Email simoncookriotintocomWeb wwwriotintomineralscom
Global CombustionSystems
Total Support
Unit 43 Evans Business Centre Easter Inch Bathgate EH48 2EH Scotland UK
Tel+44 (0) 1506 657310Fax +44 (0) 8704 799975Email SalesglobalcombustioncomWeb wwwglobalcombustioncom
TIAMA ZA des Plattes 1 Chemin des Plattes 69390 Vourles France
Tel +33 (0) 4 37 20 15 00Fax +33 (0) 4 78 07 94 50
Email marketingtiamacomWebsitewwwtiamacom
INDUSTRIAL GAS ENGINEERS U N I T D 2 B RO O KS I D E B U S IN E S S PA R K G RE E NG A TE C H AD D E RT O N M2 4 1 G S EN G L AN D
T E L E P H ON E 0 1 6 1 - 6 5 4 7 7 0 0 F A X 0 1 6 1 - 6 5 5 3 8 1 2
E-MAIL S A L E S MO N T S E L A S C O U K WWWMONTSELASCOUK
INDUSTRIAL GAS ENGINEERS
Unit D2 Brookside Business Park Greengate Chadderton M24 1GS UK
Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812Email salesmontselascouk wwwmontselascouk
MANUFACTURERS AND SUPPLIERS OF SELAS SQUARE PORT GAS amp AIR VALVES
AIR GAS
ANNEALING LEHRS
HOT END WARE HANDLING
HEAT-UP SERVICES
SCREEN PRINTINGLUBRICATING AND
COATING SOLUTIONS
RAW MATERIALS
INSPECTION
COMBUSTION EQUIPMENTCOMBUSTION
SYSTEMSBURNERS
GLASS LEVELMEASUREMENT
Glassman events visitwwwglassmaneventscom
ContactEsme Horn
T+44 (0) 1737 855136to book your space
Low-Emission Oxy-fuel Solutionsbull Oxygen amp oxygen flow control equipmentbull Global oxygen enrichment applicationsbull Cleanfirereg oxy-fuel burnersbull Start-up servicesInerting Applicationsbull Hydrogen nitrogen amp other gasesbull Enabling flow control equipment
(39101)
800-654-4567 (code 344)gigmrktgairproductscomairproductscomglass
Ware Handling Made EasyComplete intergrated Ware Handling package2 amp 3 Axis Servo StackerAdvanced Lehr Cross ConveyorWare Transfer units for ALL types of productionAdjustable pocket PushbarsWorldwide service and support teamDedicated to resolving your Ware Handling problems
Airfield Business Park Elvington York YO42 4AU UKTel 0044 1904 608999Email salessheppeecomWeb wwwsheppeecom
C
M
Y
CM
MY
CY
CMY
K
Sheppee Classified advertpdf 1 04022016 103415
Graphoidal Developments Ltd Broombank Road Chesterfield
S41 9QJ England
Tel +44 (0) 1246 266000Fax +44 (0) 1246 269269
Email salesgraphoidalcomWebsite wwwgraphoidalcom
Lubricating and Coating Solutions
for the Glass Container Industry
C
M
Y
CM
MY
CY
CMY
K
Classified Ad1pdf 1 03022016 135319
CLASSIFIEDSindd 1 31016 957 AM
倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
Plant technology
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
46
A production monitoring solutionSIL2016 has been released by Vertechrsquo a company dedicated to software solutions for the glass manufacturing industry Here Marie Cens outlines this yearrsquos updates and developments
The SIL is a modular system that provides tools for controlling the entire production process of a
glass making factory from the forming machines through to the palletisers
It features production performance follow-up quality control management fi nal product control capabilities pallet resorting follow-up management of mould set performance data mining structured and comprehensive reporting tools raw materials control management and a plant performance dashboard
Vertechrsquo invested around 25 of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution
New SIL developments are compatible with glass processes such as the press and blow process press ware tubingdrawn glass and decoration lines The SIL2016 solution can address the food and beverage perfume cosmetics and pharmaceutical industries with the goal of improving plant effi ciency
Latest developmentsThe new SIL version can not only trace production events but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped
Operators are used to reacting to these types of events but up until now the actions carried out were not recorded Thanks to automatic event forms (Fig 1) they are now able to indicate what corrective andor preventive actions were done in reaction to these events
SIL2016 is also able to highlight repeated defects on a cavity or a mould number A warning alerts the operator when repeated defects are seen at the end of their control
As the SIL production monitoring system has become more accurate and displays more information about production events it is important for managers to have an overall view of
Fig 2 The Dash-
board launched in the
SIL2015 version
Fig 3 The SILX-change is an intranet portal that allows different users to have different KPIs saved to their profi les
historical events with the option of selecting the level of details they wish to see Therefore the history view has been improved and can now be used as the basis for daily production meetings
Managers can see necessary information on a single view with required details available in tooltips displayed as they place the mouse on the events
SIL2016 also includes many improved production features quality control features and mould solutions now compatible with multi-article production confi guration
Last year Vertechrsquo introduced the smart Dashboard (Fig 2) which displays the main Key Performance Indicators at-a-glance This year Vertechrsquo introduced SILXchange (Fig 3) an intranet portal dedicated to production that has new
Fig 1 An example
of an event form
used to indicate
what actions the
operator has taken
Vertech 15indd 1 31016 952 AM
Plant technology
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
available today
PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
CLASSIFIEDS
contact us vidromecanicavidromecanicacom wwwvidromecanicacom
for Tableware and Stemware
TEMPERING LINES ON BELT SPINDLES
ANNEALING amp DECORATING LEHRS for Containers and Tableware
KBA-KAMMANN GmbH Bergkirchener Str 228D-32549 Bad Oeynhausen (Germany)
Fon +49 (0) 5734 5140-0 Fax +49 (0) 5734 5140-5130mailkba-kammanncom wwwkba-kammanncom
DECORATING MACHINES
FLEXIBLEPRECISEINNOVATIVE
Rio Tinto Minerals
2 Eastbourne TerraceLondon W2 6LG UK
Tel +44 (0) 207 781 1450Fax +44 (0) 207 781 1851Email simoncookriotintocomWeb wwwriotintomineralscom
Global CombustionSystems
Total Support
Unit 43 Evans Business Centre Easter Inch Bathgate EH48 2EH Scotland UK
Tel+44 (0) 1506 657310Fax +44 (0) 8704 799975Email SalesglobalcombustioncomWeb wwwglobalcombustioncom
TIAMA ZA des Plattes 1 Chemin des Plattes 69390 Vourles France
Tel +33 (0) 4 37 20 15 00Fax +33 (0) 4 78 07 94 50
Email marketingtiamacomWebsitewwwtiamacom
INDUSTRIAL GAS ENGINEERS U N I T D 2 B RO O KS I D E B U S IN E S S PA R K G RE E NG A TE C H AD D E RT O N M2 4 1 G S EN G L AN D
T E L E P H ON E 0 1 6 1 - 6 5 4 7 7 0 0 F A X 0 1 6 1 - 6 5 5 3 8 1 2
E-MAIL S A L E S MO N T S E L A S C O U K WWWMONTSELASCOUK
INDUSTRIAL GAS ENGINEERS
Unit D2 Brookside Business Park Greengate Chadderton M24 1GS UK
Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812Email salesmontselascouk wwwmontselascouk
MANUFACTURERS AND SUPPLIERS OF SELAS SQUARE PORT GAS amp AIR VALVES
AIR GAS
ANNEALING LEHRS
HOT END WARE HANDLING
HEAT-UP SERVICES
SCREEN PRINTINGLUBRICATING AND
COATING SOLUTIONS
RAW MATERIALS
INSPECTION
COMBUSTION EQUIPMENTCOMBUSTION
SYSTEMSBURNERS
GLASS LEVELMEASUREMENT
Glassman events visitwwwglassmaneventscom
ContactEsme Horn
T+44 (0) 1737 855136to book your space
Low-Emission Oxy-fuel Solutionsbull Oxygen amp oxygen flow control equipmentbull Global oxygen enrichment applicationsbull Cleanfirereg oxy-fuel burnersbull Start-up servicesInerting Applicationsbull Hydrogen nitrogen amp other gasesbull Enabling flow control equipment
(39101)
800-654-4567 (code 344)gigmrktgairproductscomairproductscomglass
Ware Handling Made EasyComplete intergrated Ware Handling package2 amp 3 Axis Servo StackerAdvanced Lehr Cross ConveyorWare Transfer units for ALL types of productionAdjustable pocket PushbarsWorldwide service and support teamDedicated to resolving your Ware Handling problems
Airfield Business Park Elvington York YO42 4AU UKTel 0044 1904 608999Email salessheppeecomWeb wwwsheppeecom
C
M
Y
CM
MY
CY
CMY
K
Sheppee Classified advertpdf 1 04022016 103415
Graphoidal Developments Ltd Broombank Road Chesterfield
S41 9QJ England
Tel +44 (0) 1246 266000Fax +44 (0) 1246 269269
Email salesgraphoidalcomWebsite wwwgraphoidalcom
Lubricating and Coating Solutions
for the Glass Container Industry
C
M
Y
CM
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CMY
K
Classified Ad1pdf 1 03022016 135319
CLASSIFIEDSindd 1 31016 957 AM
倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
Plant technology
Glass International March 2016
ww
wg
lass
-int
erna
tion
alc
om
47
widget library management With SILXchange Vertechrsquo has designed groups of users
for whom the plant manager can decide what information to display With SILXchange each user has their own dashboards and KPIs saved to their profile
Finally the new data extraction tool presented at the last glasstec the SILDataXtractor (Fig 4) has evolved and offers multiple possibilities for data extraction The tool is based on a new concept all searches are made depending on the date whatever the job the line the article produced or the mould
The user-friendly tool provides many filters and pivot tables to organise the data as you wish Results are displayed in easy-to-read advanced charts and historical views
A new yearVertechrsquo releases a new version of its software each year in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group
That way developments performed during the year are compiled and proposed in the next version allowing relevant improvements to be installed in every other plant that has its system upgraded
This also allows Vertechrsquo all the time necessary to test the new developments before releasing the software version with the best possible quality
Benefits Production management software is dedicated to increasing plant performance and Vertechrsquo believes the benefits generated outweigh the cost of the solution itself
A production monitoring system is a tool that concentrates all production data and displays KPIs in real time and a management dashboard to pilot the plant with more efficienct and secure data But it is also a reporting tool performing analyses and a quality tool ensuring traceability of several years
After 20 years of expertise in software solutions dedicated to the glass industry Vertechrsquo has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory r
Marie Cens Sales and Marketing Vertechrsquo Francehttpvertecheu
Fig 4 The SILDataXtractor is the companyrsquos latest data extraction tool
Fast throughput
No job change
Lab-precision volume measurement at the line
Multi-line support
AGR I N T L C O M bull +17244822163
The most advanced volume and pressure measurement system
available today
PRESSURE AND VOLUME TESTING IN ONE MACHINE
Production
Messages Notes
Losses and outputs
Set out Pallet Set out defect
Hot end losses
Machine challenging
Mould changes Samplings
Laboratory Mould
Vertech 15indd 2 31016 952 AM
CLASSIFIEDS
contact us vidromecanicavidromecanicacom wwwvidromecanicacom
for Tableware and Stemware
TEMPERING LINES ON BELT SPINDLES
ANNEALING amp DECORATING LEHRS for Containers and Tableware
KBA-KAMMANN GmbH Bergkirchener Str 228D-32549 Bad Oeynhausen (Germany)
Fon +49 (0) 5734 5140-0 Fax +49 (0) 5734 5140-5130mailkba-kammanncom wwwkba-kammanncom
DECORATING MACHINES
FLEXIBLEPRECISEINNOVATIVE
Rio Tinto Minerals
2 Eastbourne TerraceLondon W2 6LG UK
Tel +44 (0) 207 781 1450Fax +44 (0) 207 781 1851Email simoncookriotintocomWeb wwwriotintomineralscom
Global CombustionSystems
Total Support
Unit 43 Evans Business Centre Easter Inch Bathgate EH48 2EH Scotland UK
Tel+44 (0) 1506 657310Fax +44 (0) 8704 799975Email SalesglobalcombustioncomWeb wwwglobalcombustioncom
TIAMA ZA des Plattes 1 Chemin des Plattes 69390 Vourles France
Tel +33 (0) 4 37 20 15 00Fax +33 (0) 4 78 07 94 50
Email marketingtiamacomWebsitewwwtiamacom
INDUSTRIAL GAS ENGINEERS U N I T D 2 B RO O KS I D E B U S IN E S S PA R K G RE E NG A TE C H AD D E RT O N M2 4 1 G S EN G L AN D
T E L E P H ON E 0 1 6 1 - 6 5 4 7 7 0 0 F A X 0 1 6 1 - 6 5 5 3 8 1 2
E-MAIL S A L E S MO N T S E L A S C O U K WWWMONTSELASCOUK
INDUSTRIAL GAS ENGINEERS
Unit D2 Brookside Business Park Greengate Chadderton M24 1GS UK
Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812Email salesmontselascouk wwwmontselascouk
MANUFACTURERS AND SUPPLIERS OF SELAS SQUARE PORT GAS amp AIR VALVES
AIR GAS
ANNEALING LEHRS
HOT END WARE HANDLING
HEAT-UP SERVICES
SCREEN PRINTINGLUBRICATING AND
COATING SOLUTIONS
RAW MATERIALS
INSPECTION
COMBUSTION EQUIPMENTCOMBUSTION
SYSTEMSBURNERS
GLASS LEVELMEASUREMENT
Glassman events visitwwwglassmaneventscom
ContactEsme Horn
T+44 (0) 1737 855136to book your space
Low-Emission Oxy-fuel Solutionsbull Oxygen amp oxygen flow control equipmentbull Global oxygen enrichment applicationsbull Cleanfirereg oxy-fuel burnersbull Start-up servicesInerting Applicationsbull Hydrogen nitrogen amp other gasesbull Enabling flow control equipment
(39101)
800-654-4567 (code 344)gigmrktgairproductscomairproductscomglass
Ware Handling Made EasyComplete intergrated Ware Handling package2 amp 3 Axis Servo StackerAdvanced Lehr Cross ConveyorWare Transfer units for ALL types of productionAdjustable pocket PushbarsWorldwide service and support teamDedicated to resolving your Ware Handling problems
Airfield Business Park Elvington York YO42 4AU UKTel 0044 1904 608999Email salessheppeecomWeb wwwsheppeecom
C
M
Y
CM
MY
CY
CMY
K
Sheppee Classified advertpdf 1 04022016 103415
Graphoidal Developments Ltd Broombank Road Chesterfield
S41 9QJ England
Tel +44 (0) 1246 266000Fax +44 (0) 1246 269269
Email salesgraphoidalcomWebsite wwwgraphoidalcom
Lubricating and Coating Solutions
for the Glass Container Industry
C
M
Y
CM
MY
CY
CMY
K
Classified Ad1pdf 1 03022016 135319
CLASSIFIEDSindd 1 31016 957 AM
倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
CLASSIFIEDS
contact us vidromecanicavidromecanicacom wwwvidromecanicacom
for Tableware and Stemware
TEMPERING LINES ON BELT SPINDLES
ANNEALING amp DECORATING LEHRS for Containers and Tableware
KBA-KAMMANN GmbH Bergkirchener Str 228D-32549 Bad Oeynhausen (Germany)
Fon +49 (0) 5734 5140-0 Fax +49 (0) 5734 5140-5130mailkba-kammanncom wwwkba-kammanncom
DECORATING MACHINES
FLEXIBLEPRECISEINNOVATIVE
Rio Tinto Minerals
2 Eastbourne TerraceLondon W2 6LG UK
Tel +44 (0) 207 781 1450Fax +44 (0) 207 781 1851Email simoncookriotintocomWeb wwwriotintomineralscom
Global CombustionSystems
Total Support
Unit 43 Evans Business Centre Easter Inch Bathgate EH48 2EH Scotland UK
Tel+44 (0) 1506 657310Fax +44 (0) 8704 799975Email SalesglobalcombustioncomWeb wwwglobalcombustioncom
TIAMA ZA des Plattes 1 Chemin des Plattes 69390 Vourles France
Tel +33 (0) 4 37 20 15 00Fax +33 (0) 4 78 07 94 50
Email marketingtiamacomWebsitewwwtiamacom
INDUSTRIAL GAS ENGINEERS U N I T D 2 B RO O KS I D E B U S IN E S S PA R K G RE E NG A TE C H AD D E RT O N M2 4 1 G S EN G L AN D
T E L E P H ON E 0 1 6 1 - 6 5 4 7 7 0 0 F A X 0 1 6 1 - 6 5 5 3 8 1 2
E-MAIL S A L E S MO N T S E L A S C O U K WWWMONTSELASCOUK
INDUSTRIAL GAS ENGINEERS
Unit D2 Brookside Business Park Greengate Chadderton M24 1GS UK
Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812Email salesmontselascouk wwwmontselascouk
MANUFACTURERS AND SUPPLIERS OF SELAS SQUARE PORT GAS amp AIR VALVES
AIR GAS
ANNEALING LEHRS
HOT END WARE HANDLING
HEAT-UP SERVICES
SCREEN PRINTINGLUBRICATING AND
COATING SOLUTIONS
RAW MATERIALS
INSPECTION
COMBUSTION EQUIPMENTCOMBUSTION
SYSTEMSBURNERS
GLASS LEVELMEASUREMENT
Glassman events visitwwwglassmaneventscom
ContactEsme Horn
T+44 (0) 1737 855136to book your space
Low-Emission Oxy-fuel Solutionsbull Oxygen amp oxygen flow control equipmentbull Global oxygen enrichment applicationsbull Cleanfirereg oxy-fuel burnersbull Start-up servicesInerting Applicationsbull Hydrogen nitrogen amp other gasesbull Enabling flow control equipment
(39101)
800-654-4567 (code 344)gigmrktgairproductscomairproductscomglass
Ware Handling Made EasyComplete intergrated Ware Handling package2 amp 3 Axis Servo StackerAdvanced Lehr Cross ConveyorWare Transfer units for ALL types of productionAdjustable pocket PushbarsWorldwide service and support teamDedicated to resolving your Ware Handling problems
Airfield Business Park Elvington York YO42 4AU UKTel 0044 1904 608999Email salessheppeecomWeb wwwsheppeecom
C
M
Y
CM
MY
CY
CMY
K
Sheppee Classified advertpdf 1 04022016 103415
Graphoidal Developments Ltd Broombank Road Chesterfield
S41 9QJ England
Tel +44 (0) 1246 266000Fax +44 (0) 1246 269269
Email salesgraphoidalcomWebsite wwwgraphoidalcom
Lubricating and Coating Solutions
for the Glass Container Industry
C
M
Y
CM
MY
CY
CMY
K
Classified Ad1pdf 1 03022016 135319
CLASSIFIEDSindd 1 31016 957 AM
倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
倀甀琀 礀漀甀爀 搀攀昀攀挀琀猀 椀渀 琀栀攀 猀瀀漀琀氀椀最栀琀
挀愀洀攀爀愀猀 挀漀渀挀攀瀀琀Ⰰ 愀 猀甀挀挀攀猀猀昀甀氀氀 椀渀瘀攀渀琀椀漀渀 戀礀 䤀刀䤀匀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀猀
吀栀愀渀欀猀 琀漀 椀琀猀 挀愀洀攀爀愀猀 挀漀瘀攀爀椀渀最 琀栀攀 昀甀氀氀 戀漀搀礀 漀昀 琀栀攀 挀漀渀琀愀椀渀攀爀Ⰰ 琀栀攀 最氀愀猀猀 椀渀猀瀀攀挀琀椀漀渀 洀愀挀栀椀渀攀 䔀瘀漀氀甀琀椀漀渀 漀昀昀攀爀猀 㘀 愀渀最氀攀猀 漀昀 猀栀漀漀琀椀渀最Ⰰ 攀愀挀栀 栀愀瘀椀渀最 挀愀洀攀爀愀猀㨀ⴀ 䄀 栀椀最栀 爀攀猀漀氀甀琀椀漀渀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 甀瀀瀀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀 嘀椀攀眀 琀栀攀 渀攀挀欀 甀瀀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀 昀爀漀洀 愀戀漀瘀攀ⴀ 䄀渀漀琀栀攀爀 挀愀洀攀爀愀 愀渀愀氀礀猀攀猀 琀栀攀 氀漀眀攀爀 瀀愀爀琀 漀昀 琀栀攀 戀漀琀琀氀攀Ⰰ 昀爀漀洀 琀栀攀 戀愀猀攀 琀漀 琀栀攀 猀栀漀甀氀搀攀爀
匀匀琀爀攀猀猀 椀渀猀瀀攀挀琀椀漀渀 椀猀 瀀攀爀昀漀爀洀攀搀 甀猀椀渀最 琀栀攀 猀愀洀攀 氀椀最栀琀 猀漀甀爀挀攀猀 愀渀搀 㐀 愀搀搀椀琀椀漀渀愀氀 挀愀洀攀爀愀猀 搀攀搀椀挀愀琀攀搀 琀漀 猀琀爀攀猀猀 搀攀琀攀挀琀椀漀渀
嘀䤀匀䤀吀 唀匀 伀一 䌀䠀䤀一䄀 䜀䰀䄀匀匀 ⴀ 匀栀愀渀最栀愀椀 ⴀ 琀漀 㐀 䄀瀀爀椀氀 㘀一攀眀 䤀渀琀攀爀渀愀琀椀漀渀愀氀 䔀砀瀀漀 䌀攀渀琀攀爀 ⴀ 䠀愀氀氀 圀 ⴀ 匀琀愀渀搀 㔀 眀眀眀椀爀椀猀ⴀ椀洀挀漀洀
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237
studiobrandit
wwwbdfit
Melting | Forming | Automation | Energy
All in one
1906-2016110th anniversary
A great vintage stays forever
This year we are celebrating 110 yearstogether while looking forward to excitingnew challenge for the time to comeThank you for trusting and believing in ourlove for tradition passion and innovation
Your trust and loyalty are our success
ADV_bdf_2016_OKindd 1 050216 1237