EMHART GLASS HORN GLASS INDUSTRIES …var.glassonline.com/uploads/publications/riviste/GM_2-10.pdfLIGHTING • PHARMACEUTICAL GLASS• SODIUM-SILICATE GLASS• TABLEWARE• TUBING

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YEAR 23 ISSUE NO. 2/2010 MARCH/APRIL

Issue distributed at:

CER-GLASSBUCAREST Romania11-15 May

CAIRO Egypt13-15 May

GLASS WORLDEGYPT

EMHART GLASSSPEAKING TO THE SPECIALISTS- WITH PERFECTION IN MIND

HORN GLASS INDUSTRIESCOMPLETE AND COMPREHENSIVE ENGINEERING FOR THE GLASS INDUSTRY

MERKADTOTAL QUALITY ASSURANCEFROM DESIGN TO PRODUCTION

VIDROMECANICATHERMAL-SHOCK MACHINESTESTING THE RESISTANCE OF HOLLOW GLASS TO THERMAL CHANGES

GLASS TECHNOLOGIESA NEW APPROACH TO BATCH CHARGING

Copertina GM 2-10 1-04-2010 10:17 Pagina 1

STRADA DI GABBRICCE, 6 - P.O. BOX 30 - 53035 MONTERIGGIONI (Siena) - ITALYTel. +39-0577-304730 - Fax +39-0577-304755 - [email protected] - www.fonderievaldelsane.com

F.Valdelsane 1 pag 29-03-2010 9:45 Pagina 1

MIR STEKLA 1 pag 6-04-2010 9:54 Pagina 1

Fluorital 1 pag 29-03-2010 9:41 Pagina 1

E N G I N E E R E D I N G E R M A N Y

Every new project has an element of risk, which is why you should rely on a market leader to support you: HORN.

HORN’s global reach, expertise in structuring client specific solutions com-

bined with outstanding “all-round service” (from planning to after sale

maintenance) ensure more than the latest innovations and an excellent

return on investment, they also mean complete peace-of-mind.

In fact, more than 20,000 tons of glass produced internationally with

HORN plants and machinery each day – trouble-free! So, take the pressure

off yourself, contact us today.

www.hornglas.de

risk is relative

It all depends on who you have on your side.

CONTAINER GLASS • COSMETIC GLASS • FIBRE GLASS • FLAT GLASS • FLOAT GLASS LIGHTING • PHARMACEUTICAL GLASS • SODIUM-SILICATE GLASS • TABLEWARE • TUBING

Horn 1 pag 6-04-2010 9:54 Pagina 1

S.I.G.MA. Srl - Via delle Grigne 12/A - Locate Varesino (CO) - 22070 Italytel. +39 0031 823195 - fax +39 0331 823198www.sigmaref.it - e-mail: [email protected]

Sigma 1 pag.qxd 6-04-2010 9:55 Pagina 1

BDF 1 pag 6-04-2010 9:55 Pagina 1

Busellato Glass Moulds means innovation and technology and, thanksto the experience of its well-trained staff and technicians, the company isable to satisfy the most demanding client requests.

Accuracy, together with considerable experience in metallization, guarantees high quality products, while RINA certification represents our aimof offering reliable service to our clients. This service includes advice, cooperation, also suggesting changes and improvements., thanks to ourmany years of worldwide collaboration and knowledge of diverse markets.The strong commitment to our work, along with the use of sophisticatedmachinery and research are the strong points of Busellato Glass Moulds,together with our aim of being a leading company and not a follower.

This continuous commitment and a series of generational changes overthe past few years have made for higher quality requirements whichBusellato Glass Moulds meets thanks to continuously ongoing develop-ments of new technologies.

Busellato 1 pag 6-04-2010 9:56 Pagina 1

GLASS SERVICE s.r.l - ITALYtel.+39.0571.4442fax [email protected]

HOT TECHNOLOGYglass machinery

CYBERGLASSR O B O T I C S

STRAIGHT TO THE POINT

SOLUTIONS FOR THE GLASS INDUSTRY

batch plants melting furnaces forehearths robotics forming machines

Glass Service 1 pag 6-04-2010 9:56 Pagina 1

Vial Production LinesAmpoule Production LinesDental Cartridge LinesDropper & Test Tube Lines

Ampoule Production LinesVial Cartridge Processing LinesDental Cartridge Processing LinesSprinkler Production Lines

[email protected]

a company of OCMI-OTG S.p.A.

One waythe best line for the best glass tube

There’s only

The OCMI-OTG group, together with MODERNEMECANIQUE , is leader manufacturer of machineryfor the production of tubular pharmaceutical andcosmetic glass containers. Such as : ampoule, vial,cartridges, syringes, glass dropper.

Ocmi OTG 1 pag 6-04-2010 9:57 Pagina 1

7

cont

ents

Year 23 • no. 2/2010 (131)March/April

THEGLOBAL

PARTNER

OLIVOTTO GLASS TECHNOLOGIES GROUP

Avigliana • Viale Gandhi, 22 • 10051 Avigliana (TO) • Italy • Tel. +39 011 9343511 • Fax +39 011 9343592

Caronno P. • P.zza Pertini, 75 • 21042 Caronno P. (VA) • Italy • Tel. +39 02 96190611 • Fax +39 02 96190636

Bainbridge • 207 Airport Road • Bainbridge, GA 39817 USA • Tel. +1 229 2482345 • Fax +1 229 2430987

Grafenau • W. Sedlbauer Str. 12 • D94481 Grafenau • Germany • Tel. +49 8552 9656 12 • Fax +49 8552 1410

www.olivotto.it

HOLLOW GLASS FORMING TECHNOLOGIESA FULL KNOW HOW FROM ITALY, USA AND GERMANY

PUBLISHER/EDITOR-IN-CHIEFMarco Pinetti .......................... [email protected]

ASSOCIATE EDITORValerie Anne Scott .................... [email protected]

ADVERTISINGIITTAALLYY

Maurizio Lozza .................. [email protected]

WWOORRLLDDWWIIDDEE

Luciano Molina .................. [email protected]

GRAPHIC DEPARTMENTSonia Previato .................... [email protected]

Elisabetta Turani ........................ [email protected]

SUBSCRIPTIONSBarbara Maresca ............ [email protected]

PRINTED BYFABIANO GROUP SrlReg. San Giovanni 40 - 14053 Canelli (AT) - Italy

BACK COPIES€ 29 air mail included Italy: € 15

Entire contents © 2010 by ARTENERGY PUBLISHING S.r.l. Allrights reserved. Reproduction even partially in any form is strictlyprohibited unless written permission has first been obtained fromthe Publisher. The magazine is open to collaboration from all, butno manuscripts or photographs will be returned. The editor’s officedoes not accept responsibility for opinions expressed in signedarticles. Court responsible: Milan. Publication registered at no. 4 ofthe Milan Court Records Office on 11.1.1988 - ISSN 0394-9893

Glass Machinery Plants & Accessories, n. 131, anno 23, 2010, Dir. Resp. Marco Pinetti.

Periodico bimestrale. COVER ADVERTISER:OLIVOTTO GLASS TECHNOLOGIES

Viale Gandhi, 22 - 10051 Avigliana (TO) - ItalyTel.: +39-011-9343511 - Fax: +39-011-9343593

E-mail: [email protected] - www.olivotto.it

glass machinery plants & accessories 2/2010

&regular features11 ADVERTISERS INDEX

ALL COMPANIES MENTIONED

12 OUR FAIRS CALENDAR 2010

13 NEWS AND PRODUCTS

33 WORLD GLASSWARE INDUSTRY DIRECTORY 2010 - FREE LISTING

59 SUPPLIERS GUIDE - YELLOW PAGE

62 SUBSCRIPTION SERVICE

CER-GLASS 11-15 MAY / BUCAREST - ROMANIA

GLASS WORLD EGYPT13-15 MAY / CAIRO - EGYPT

Issue distributed at:

Via Antonio Gramsci, 57 - 20032 Cormano (Milano) - ItalyTel.: +39 - 02 - 66306866, Fax: +39 - 02 - 66305510

E-mail: [email protected]

IS PUBLISHED EVERY TWO MONTHS BY

NEW WEB SERVICE: download the magazines

free-of-charge

Contents GM 2-10 1-04-2010 10:21 Pagina 7

8 glass machinery plants & accessories 2/2010

36

24article24 INTERVIEW

Emhart Glass: speaking to the specialists - with perfection in mind

36 HOT-END EQUIPMENT

Horn Glass Industries: complete and comprehensive engineeringfor the glass industry

43 MOULDS

Merkad: total quality assurance from design to production

47 GLASS CONTAINERS

Vidromecanica: thermal-shock machines testing the resistance of hollow glass to thermal changes

50 MELTING TECHNOLOGY

Glass Technologies: a new approach to batch chargingAlfeo Caputo, Marco Ferrari

GLASS TECHNOLOGIES

54 MEETINGS

International Commission on Glass prepares for the new decade

43

cont

ents

47 50

54

Emmeti 1 pag 6-04-2010 9:57 Pagina 1

SIPAC 1 pag 6-04-2010 9:58 Pagina 1

NEW WEB SERVICE:

download

the magazines

free-of-charge

companies mentionedadvertisers index&

COMPANY NAME PAGE NO. COMPANY NAME PAGE NO. COMPANY NAME PAGE NO.

…in this issue of GMP&A. Advertisers are indicated in bold

Amig .................................... 6, 59-61

Antonini.............................. 15, 59-61

Ardagh Glass .................................. 23

BDF Industries....................... 3, 59-61

BMT ................................................. 18

British Glass...................................... 20

Busellato Glass Moulds ........ 4, 59-61

Consol............................................. 15

Corning ........................................... 22

Corning Glass Works........................ 22

Corning Museum of Glass .............. 22

Dura Temp ...................................... 23

Ecotecne ........................................ 21

Emhart Glass.............................. 24-32

Emmeti ................................ 9, 59-61

Fluorital ................ 59-61, Back cover

Fonderie Valdelsane ..........................

....................Front inside cover, 59-61

Gerresheimer ............................ 19, 22

Glass Alliance ................................. 32

Glass Service ....................... 5, 59-61

Glass Technologies .................... 50-53

Glassman Middle East .................... 30

glasstec 2010 ................................. 26

Glasstech Asia .............................. 64

Hindustan Glass ........................ 17, 18

Horn.................................. First page,

................................32, 36-42, 59-61

International Commission

on Glass..................................... 54-58

Johns Manville ................................ 18

KYP Accessories ................. 19, 59-61

Lafarge ........................................... 13

Libbey ............................................. 13

Merkad....................................... 43-46

Mir Stekla .............. Back inside cover

Moderne Mecanique .......... 6, 59-61

MSK ................................................. 32

MT Forni Industriali ............... 6, 59-61

O-I................................................... 16

OCMI OTG ........................... 6, 59-61

Olivotto-Antas-Lynch-Lindner .............

..............................Front cover, 59-61

OMCO ...................................... 13, 18

Owens Corning ............................... 20

Piramal Glass .................................. 14

PPG ................................................. 23

Protatherm ...................................... 23

Quinn Glass..................................... 23

Ripple Glass .................................... 20

S.I.G.MA. .............................. 2, 59-61

Saint-Gobain Containers................. 13

Sipac.................................. 10, 59-61

Steuben Glass ................................. 22

Teichmann, Henry F. .......... 17, 59-61

Vidromecanica.......................... 47-49

Zippe......................................... 18, 32

Companies M. + Adv. Index GM 2-10 1-04-2010 10:28 Pagina 15

ALL GLASSTEC EXHIBITORS WHO ADVERTISE IN THIS ISSUE WILL ALSO RECEIVE A FREE GLASSTEC PREVIEW ▼ ▼

20

10FAIR

CALENDARissue exhibition/conference date venue insert

1 FEBRUARYPublication date:

20

10 2

20

10 1

20

10 3

GLASSMANSOUTH AMERICA 9-10 March SÃO PAULO

Brazil

GLASS-TECHPOLAND 9-11 April

KIELCEPoland

19 APRIL

10TH ESG CONFERENCE

30 May2 June

MAGDEBURG Germany

CHINA GLASS 4-7 JuneBEIJING China

20

10 5

25 AUGUST

GLASSTEC 28 September1 October

DÜSSELDORFGermany

22 MARCH

GLASS WORLDEGYPT 13-15 May

CAIRO Egypt

CER-GLASS 11-15 MayBUCARESTRomania

CHINESE SUPPLIERS GUIDE / YELLOW PAGES RESERVED FOR ADVERTISERS OF THIS ISSUE ▼ ▼ ▼

20

10 6

TO BE ANNOUNCED

EMBALLAGE 22-25November

PARIS France

GLASSPEX INDIA 12-14January 2011

MUMBAIIndia

CONF. ON GLASSPROBLEMS

19-20October

COLUMBUS (OH)USA

AFGM - ASEANGLASS CONFERENCE

OctoberSOUTHEAST ASIA

THIS ISSUE WILL ALSO PRESENT THEAGENTS WORLD GUIDE 2011, 16TH EDITION ▼ ▼ ▼

20

10 4

3 MAY

HOLLOWGLASSASIA

29 June1 July

SINGAPORE

MIR STEKLA 7-10 JuneMOSCOWRussia

RUSSIAN SUPPLIERS GUIDE / YELLOW PAGES RESERVED FOR ADVERTISERS OF THIS ISSUE ▼ ▼ ▼

▼

16TH

provisional

Publication date:

Publication date:

Publication date:

Publication date:

Publication date:

• AUTOMATIC PRESSES • FULLY ELECTRONIC PRESS & BLOW MACHINES

• AUTOMATIC BLOW-BLOW MACHINES • MODULAR PRESS & BLOW MACHINES FOR MEDIUM-LOW

SPEED PRODUCTION • PRESS-BLOW-BLOW MACHINES FOR HIGH-QUALITY PRODUCTION

• BLOWING MACHINES FOR LIGHTINGWARE AND LARGE CONTAINERS • DANNER TYPE TUBING LINES

• AUTOMATIC SPINNING MACHINES • FIRE POLISHERS • BURN-OFF MACHINES

• STRETCHING MACHINES • GLASS BRICK LINES • GLASS INSULATOR LINES • FEEDERS FOR ANY TYPE

OF GLASS AND SPEED • USER-FRIENDLY-FULLY-ELECTRONIC SYSTEMS • WELDING/STRETCHING MACHI-

NES • MULTIFUNCTION STEMWARE LINES • STRETCHING/BURN-OFF MACHINES

Range of products

THEGLOBALPARTNER

OLIVOTTO GLASS TECHNOLOGIES GROUP

www.olivotto.it

HOLLOW GLASS FORMING TECHNOLOGIES

A FULL KNOW HOW FROM ITALY, USA AND GERMANY

Visit us at GLASSTECDüsseldorf - GermanyHALL 14 - STAND E62

Paolo Panza Tableware Technologies ManagerAndrea Valle Tubes & Lighting Technologies Manager

Antonio Cesaretto Technical Glasses Technologies Manager

Elia RizziRichard Robinson > Sales ManagersSergio Sarvia Managing Director & Technical Manager

Peyton Dixon Sales Area ManagerRandall Brouillet Technical Manager

People to contact at our stand

THIS AD ON PAGE 16 ORSEE THE SUPPLIERS GUIDE SECTION

HALL 14 STAND E62 Products being promoted

Martin Jetter President Franco Venturelli Vice President of Sales

Representatives of Emhart Glass

People to contact at our stand

For almost a century, Emhart Glass has stood for stabi l i ty . At

every step, you will feel the reassurance of dealing with a global

leader in the glass container industry. With an internat iona l

network covering all five continents, we are there for you at the

right time and in the right language, offering a tota l approach

that combines a true ‘end to end’ product range with advice,

technical assistance and production support. Looking to the

future, we are committed to invest ing in the innovations that

will shape tomorrow’s glass production: efficiency, ease of use,

reliability and environmental care. And we deliver all this

through partnersh ip that is focused on the best possible

return on investment for you and your customers.Emhart Glass – partnering for perfect packaging solutions.

Emhart Glass SA · Hinterbergstrasse 22 · PO Box 2251 · CH-6330 Cham 2 · Switzerland · Telephone: +41 41 749 42 00 · www.emhartglass.com · Europe, Asia, USA

INTERNATIONALITY

THIS AD ON BACK INSIDE COVER ORSEE THE SUPPLIERS GUIDE SECTION

HALL 13 STAND B41

The products planned to be on display include the latest NIS section,

configured for quad gob, a new parallel blank open mechanism for the

small section, Plunger Process Control, FlexPusher, InVertiFlow, 360°

Auxiliary cooling, and mold temperature measuring equipment.

On the Cold End side, Emhart Inex will introduce its latest developments

in on-line glass container inspection including advanced check

and vision capabilities, improved operator interfaces, and new technical

service advancements. In addition, we will exhibit the most

comprehensive line of automated statistical measurement machinesavailable today.

Calendario GM 2_10 26-03-2010 12:29 Pagina 1

news& PRODUCTS


13

LIBBEYSENIOR SECUREDNOTES TO REFINANCEEXISTING DEBT

Libbey Inc. announcedon 22 January that its

wholly owned subsidiary LibbeyGlass Inc. plans to issue USD400.0 million aggregate princi-pal amount of senior securednotes due 2015 in a privateplacement. Libbey Glass intendsto use the net proceeds from thesale of the Notes, together withcash on hand, to repurchase itsexisting USD 306 millionFloating Rate Senior SecuredNotes due 2011 in a tender offerwhich were expected to launchon 25 January 2010; as well asto repay its USD 80.4 millionSenior Subordinated SecuredPayment-in-Kind Notes due2021; and related fees and expens-es. The sale of the Notes is contingent upon the entry intoa new USD 110 million senior secured asset-based revolv-ing credit facility by Libbey Glass and its direct whollyowned subsidiary Libbey Europe B.V., as borrowers, andLibbey and certain of Libbey Glass' existing and futuresubsidiaries as guarantors.

Based in Toledo, Ohio, since 1888, the company oper-ates glass tableware manufacturing plants in the UnitedStates, Mexico, China, Portugal and the Netherlands.

SAINT-GOBAIN CONTAINERS and LAFARGESETTLEMENT WITH E.P.A.

On 21 January 2010 two major settlements weremade for the reduction of emissions from 28 glass

and cement plants, found to be violating the Clean Air Actby emitting excessive amounts of sulphur dioxide, nitro-gen oxides and particulate matter each year, according toCynthia Giles, assistant administrator for the

Environmental Protection Agency's (E.P.A.) office ofenforcement and compliance assurance.

According to the E.P.A. and the Justice Department,the two companies - Saint-Gobain Containers andLafarge Company - will spend more than USD 100million to install pollution control equipment. They willalso pay a combined USD 7.2 million in fines.

The settlements involved 15 plants owned by Saint-Gobain Containers, and 13 plants owned by Lafarge.

“The pollutants we targeted here make a real differenceto people's health,” Ms. Giles said. “They contribute torespiratory illnesses and heart disease.”

Assistant attorney general in the Department ofJustice's environment and natural resources division,Ignacia Moreno, said the settlements were a warning toother violating companies to “take notice.”

“Business as usual is not going to pay any longer,” shesaid. “We're talking about system-wide change.”

As part of the strategy to constantly improve the quality of its productsand service, OMCO International has implemented a group-wide

UKAS compliant Quality Management System. This resulted in certification toISO 9001:2008 being granted in December 2009.

According to Colin Webster, Group Quality manager, the QMS will form thefoundation for a consistent quality standard in all sites throughout the group.This will further enhance OMCO’s position as a leading mould manufacturer.

OMCO International was established in Belgium in 1964. Over the years,OMCO has become a group of seven manufacturing plants that supply a full rangeof glass container moulds and accessories to glass plants throughout the world.

OMCOISO CERTIFICATION

www.glassonline.comCLICKHERE

B&P NEWS GM 2_10 1-04-2010 10:31 Pagina 13

news& PRODUCTS


14

PIRAMAL GLASSGROWTH CONTINUES

Consolidating its turnaround, on 22 January 2010Piramal Glass Limited (PGL) reported sub-

stantial growth in its third-quarter results for FY 2010.The company reported consolidated sales for the quarterended 31 December 2009 with a 4.4% increase to INR 2.8billion compared to third-quarter FY 2009 results.

Operating profit was up 46.4% to INR 625.0 millionand Operating Profit Margin (EBITDA Margin) was high-er at 21.8% compared to 15.5% in the same period of FY2009. Net Profit for the period was INR 113.0 millionagainst Net Loss of INR 382.0 million for the same peri-od in 2009, which marks a turnaround of US operations.

For the nine months ended December 2009, total saleson a consolidated basis increased 9.8% to INR 8.2 bil-lion compared to the same period in FY 2009, whileOperating Profit was up to INR 1.7 billion as comparedto INR 1.2 billion in the nine-month period of FY2009. Operating Profit Margin for the nine months wasalso higher at 20.4% compared to 16.1% in the sameperiod of FY 2009. Net Loss was INR 89.7 millioncompared to INR 665.6 million during the same periodin 2009.

PGL operates in three major business segments - cos-metics and perfumery (C&P), speciality food and beve-rages (SF&B) and pharmaceuticals. Sales from the C&Pdivision for the quarter ended December 2009 increased11.8% at INR 1.2 billion, while the pharma divisionrecorded sales of INR 839.8 million in the third quarterof FY 2010 compared to INR 938.0 million in the sameperiod of FY 2009. SF&B continued to record stronggrowth and jumped 13.1% to INR 768.7 million, withthe strong demand for PGL's products from Sri Lankafacility resulting in 137.0% higher export revenues forthe quarter.

During the same quarter, revenues of the company's USsubsidiary - Piramal Glass USA Inc., increased 13.8% toINR 914.4 million. Operating Profit at (EBITDA) washigher at INR 88.4 million in the third quarter of FY2010 compared to Operating Loss of INR 81.4 million inthe same quarter of FY 2009, and is the first time, sincethe acquisition of the US subsidiary, that the company hasreported a positive operating margin of 9.5% compared toa negative 10.4% in the third quarter of FY 2009.

PGL reported a significant turnaround with Net Profitof INR 14.8 million compared to Net Loss of INR 157.3million during the same period of 2009. For the ninemonths ended December 2009, PGL's C&P divisionjumped 6.0% to INR 3.5 billion, while the Pharma divi-sion registered sales of INR 2.5 billion as compared toINR 2.6 billion in the nine-month period of FY 2009.SF&B continued its growth momentum and registered an

impressive growth of 37.6% compared to the same periodof FY 2009 to INR 2.2 billion thanks to the 210.0%increase in exports to Sri Lanka.

Piramal Glass USA Inc. also recorded strong sales ofINR 2.6 billion compared to INR 2.5 billion during thenine-month period of FY 2009, and is the first time ope-rating margin changed direction by 8.9% and became pos-itive, reaching INR 171.2 million compared to a negativeof INR 60.1 million during the same period in 2009. NetLoss was INR 85.8 million compared to INR 244.8 mil-lion in the nine months of FY 2009. Piramal Glass hasthus moved back to profits in the second quarter of FY2010 after 15 consecutive quarters of Net Losses and is ontrack to beating the guidance set at the beginning of thefinancial year.

EXPORTS BOOST PROFITSPiramal Glass Ceylon said rising exports contributed

in its profit in the December 2009 quarter, the company'ssecond successive quarterly profit after six consecutivequarters in the red.

The firm, based in Sri Lanka, is a unit of India'sPiramal Glass, reported a net profit of LKR 28.7 millionin the December 2009 quarter compared with a loss ofLKR 53.6 million rupees the previous year.

Sales during the quarter for Piramal, the sole containerglass manufacturer in the domestic market, increased 11.8%to LKR 909.5 million, and, according to chief exe-cutiveSanjay Tiwari, the increase in sales during the quarter wasonly due to the increase in exports, which totalled LKR 243million rupees, an increase of 241% compared to a year ago.Earnings per share for the December quarter were LKR 0.03compared to a loss of LKR 0.06 the previous year.

The statement also said the company converted morethan half of its long-term rupee debt to foreign currencyloans in November 2009 with the same consortium ofbanks, during its aim to reduce costs.

The two successive quarters of profit helped the com-pany to reduce losses in the nine months ending 31December 2009, which ended with a loss of LKR 89 mil-lion, compared to LKR 207 million for the same periodthe previous year.

During the nine months ending 31 December 2009,sales were up 19% to LKR 2.7 billion compared to theyear before. Exports during the nine months increased to34% of total revenue, while they were 13% in same peri-od the previous year.

During the nine months under review, Piramal'sexports were 20,000 tonnes, consisting of more than 73million bottles.

The company has a domestic market share of 88% andhas a future strategy aimed at the export of speciality,value-added liquor and boutique wine bottles to marketssuch as India, Australia and South Africa.

B&P NEWS GM 2_10 1-04-2010 10:31 Pagina 14

news& PRODUCTS

15

CONSOLNEW NIGEL GLASS FACTORYGETS INVESTMENTS

Consol, Africa's largest glass manufacturer,announced on 1 March 2010 that it intends to

build a new ZAR 1.9-billion glass factory in Nigel,boosting its annual output by 25%.

According to managing director Mike Arnold, the newglass factory will increase the group's annual productionby 220,000 tons to over one million tons, more thanfour billion glass containers, thus ensuring sufficientproduction capacity to meet foreseeable market growthexpectations.

The new glass factory will be a two-furnace opera-tion, each with an output of 400 t/d and will be built intwo phases.

The first phase: infrastructure development, the produc-tion service equipment and the first of two furnaces, will

cost ZAR 1.3-billion, and will be commissioned bySeptember 2011.

The installation of the second phase, at a cost of ZAR600-million, will depend on, and be driven by, marketgrowth and demand. Moreover, with all infrastructure andservices already in place, the lead-time for installation andcommissioning of the second furnace should be less thannine months.

In addition to the expansion at Nigel, Consol alsoplans to increase production capacity in the WesternCape by a further 10%, or 30,000 t/y, to take place du-ring the rebuild of the Consol Bellville No 4 furnace inlate 2011 or early 2012. This expansion will increaseannual production capacity of glass containers to 1.1million tons.

"In addition to this already sizeable investment, ourfuture capital expenditure plans also include the provi-sion of a new cullet processing plant at our Wadevilleand Bellville sites. This will ensure that we are in aposition to maximize glass recycling in South Africa,"Arnold concluded.

B&P NEWS GM 2_10 1-04-2010 10:31 Pagina 15

news& PRODUCTS


16

O-ICHARLOTTE PLANT TO CLOSE

Owens-Illinois Inc. (O-I) has announced that itsmanufacturing plant in Charlotte, US, which

employs 137 people, will close on 1 May 2010, due to adecline in demand among food container customers,spokeswoman Stephanie Johnston said. The plant, locat-ed at 500 Packard Highway, and in the area since 1963,manufactures glass containers for consumer products.

According to a statement from Miguel Escobar, presidentof Owens-Illinois North America, the Charlotte plant is oneof the company's highest cost operations in North America.

Most employees will receive some form of severance,though details were not clear, and company and union offi-cials plan to meet soon to discuss details, according to O-I.

However, according to Bob Sherer, executive director ofthe Capital Area Manufacturing Council, the manufactur-ing sector in the Lansing area has shown signs ofimprovement after losing 8,000 jobs from 2000 to 2008.

PRODUCTION RESUMES AT TOANOO-I announced at the end of January 2010 that its

Toano, Virginia glass plant would resume making bottleson 1 February, even if on a limited scale, thus confirmingprevious reports.

According to the company, the new contract has a dura-tion of up to six weeks thanks to the big gap caused byAnheuser-Busch InBev pulling out.

The Toano plant will also get jobs caused by the clo-sure of O-I plants in Pennsylvania and Michigan.

“We have informed all employees at our Toano plantthat we plan to diversify the mix of products at the plantby re-machining the plant to produce food and spirits con-tainers, as well as beer bottles,” spokesman StephanieJohnston said.

O-I has announced the closure of its plants in Clarion,Pennsylvania, and Charlotte, Michigan, and is also layingoff 200 workers in Oakland, California, affecting morethan 700 employees.

AB InBev remains “a major O-I customer,” Johnstoninsisted, but declined to comment on the specific localagreement.

“We will earn higher profit margin percentages on thisbusiness, and attain greater margin stability in the future,”CEO Al Stroucken pledged.

“To achieve these objectives, shipment levels in theregion will likely decline. As a result, we will incur addi-tional temporary production curtailments in the first halfof 2010 until we permanently reduce capacity due to thischange in business mix.”

According to Johnston, the Toano plant, closed since 18December 2009, will not resume full capacity for another3-5 months, despite the increase of jobs from up north.

“It does represent good news for our employees at aplant that has been a top performer in our North Americanregion,” she said. “By diversifying production, we're tak-ing advantage of the plant's efficiency and cost effective-ness, and making the plant stronger and better positionedfor the long term.”

Q4 EPS UP, 2010 OUTLOOK OPTIMISTIC

O-I reported fiscal fourth-quarter EPS of USD 0.49, ex-items, beating consensus estimates of 47 cents, at the endof January 2010.

Stroucken, commenting on the company's fiscal 2010outlook, said, "Globally, higher prices should more thanoffset cost inflation, which we anticipate will remainmodest throughout the year. As the economy continuesto recover, we expect global glass shipments willimprove from the prior year. Results should benefit fromlower fixed costs due to the company's strategic foot-print initiative, while non-operational costs willincrease primarily due to higher pension expense.Despite the challenges of the global economic recessionduring the past two years, O-I enters 2010 well posi-tioned to drive profitable growth as markets recover andwe execute on our strategic priorities."

EFFORTS TO SAVE GLASS PLANT SO FARUNSUCCESSFUL

Despite a number of collaborative efforts with othercounty officials, the Clarion County (Pennsylvania)Commissioners said on 16 February 2010 that the localO-I glass plant is still scheduled to close in July.

O-I executives informed local workers about the shut-down at the end of January.

A meeting was held between local officials and O-Ileaders 12 February, which was attended by O-I corporateleaders on site and via conference call, elected officials,legislative aides, as well as labour union officials and rep-resentatives from various local organizations.

During the meeting, O-I officials said that the primaryreason for closing the Clarion plant is over-capacity inNorth American operations, as well as the age of its man-ufacturing facility and the high costs of renovations inorder to raise production to company standards.

According to information released from the meeting,O-I plants in Michigan and California are also involvedin reduced or shutdown operations, with work moving tofactories in Auburn and Toano, while there was nothingsaid with regards to the potential sale of the ClarionBorough property.

The commissioners said that some of the plant's equip-ment, including a proprietary heating system, wouldprobably be moved to other O-I facilities.

B&P NEWS GM 2_10 1-04-2010 10:31 Pagina 16

Serving the Glass Industry for Over 6 Decades

• Reduces NOx

• Improves Glass Quality

• Enhances Fuel Efficiency

• Increases MelterThroughput

• Longer FurnaceCampaign

Henry F. Teichmann, Inc.Engineers and Contractors to the Glass Industry

3009 Washington Road

McMurray, PA 15317-3202, USA

Fax: +1 (724) 941-3479 www.hft.com

+1 (724) [email protected] [email protected]

news& PRODUCTS

HINDUSTAN GLASSINVESTMENTS IN STATE-OF-THE-ARTGLASS MANUFACTURING UNITS

Hindustan National Glass and IndustriesLimited (HNG) has announced its intentions to

set up its state-of-the-art glass manufacturing complex atNaidupet, in the Nellore district of India.

Company joint managing director Mukul Somany saidthat HNG would set up a 'mega manufacturing complex'to produce container glass and float glass, involving aninvestment of INR 1,000 crore. He also proposed to cre-ate a 'Glass Complex' for container glass production withan investment of INR 480 crore.

Construction of the 600 tons per day float glass plantwill commence in early 2012 and will be completed by2014, while construction of the container glass plant willstart by 2014 and production will commence in mid-2016.

The container glass plant will, in the first phase,manu-facture 450 tons per day of container glass and pro-vide direct and indirect employment for 1,500 people.

REQUEST TO ABOLISH CUSTOMS DUTYON SODA ASH

Somany has communicated his budget expectations forthe packaging industry and said that the Indian packagingindustry is valued at approximately INR 650 billion, withannual growth of 15%, almost double that of the globalpackaging industry, reflecting the important potential ofthis segment in India.

To boost the Indian packaging segment further, HNGsaid it expects the central government to continue lower-ing excise duty on various commodities, as it did in FY09-10. The company also looks forward to the removal ofsoda ash customs duty, which accounts for 10-12% of theproduction costs of the glass products, while, according tothe company, the import duty on packaging machineryshould also be entirely removed.

HNG's suggestions are as follows:• removal of customs duty on soda ash;• total removal of import duty on packaging machinery;• continue in decrease of excise duty on glass packaging

to boost employment;• decrease in input costs on capital goods, infrastructure

development, new technology, etc. for the domesticpackaging industry, where most FMCG companieshave expectations from this year's budget.These reductions in excise duties and inputs costs for

packaging companies, combined with the removal of cus-toms duty on soda ash would, according to HNG, drivethe growth in the processed foods sector for domestic con-sumption, as well as exports.

B&P NEWS GM 2_10 1-04-2010 10:32 Pagina 17

news& PRODUCTS


18

ZIPPEINTENSIFYING BATCHPREHEATING TECHNOLOGY

Preheating of batch and cullet by means of fur-nace combustion gases still creates great interest

in the international glass industry, also certified by theconsiderable number of inquiries for efficiently operatingsystems meeting set requirements.

The industry is continuously evaluating the possibili-ty of reducing melting energy, lowering carbon dioxideemissions and supporting environmental protection.

Plants installed several years ago by ZIPPE in thecontainer glass industry have, and still are, showingremarkable results, thanks to the German company’s com-mitment and development work in this field.

ZIPPE is also continuing its work on advanced preheat-ing technology and the former lim-itation of batch and cullet mix-ing ratio no longer exists. Infact, the range of applications iscontinuously increasing.

A new generation preheater ispresently undergoing tests atproduction scale, with promisingresults, and will soon be will beintroduced to the glass industryand offered to the market.

Further information is avail-able for those interested.

JOHNSMANVILLESUPPORT FOR HOMESTAR ENERGY EFFICIENCY PROGRAMME

US Johns Manville,a leading global manu-

facturer of an extensive line ofenergy-efficient building prod-ucts, was present in Savannah,Georgia, with President Obama,to support a proposed energy-efficiency programme that

intends to create jobs and help families save money onenergy costs. As per the programme, consumers can beeligible for rebates between USD 1,000 and USD 1,500for home upgrades such as adding insulation and sealingleaky ducts. Those undertaking home energy audits, andthen making changes to reduce energy costs by at least20%, will be eligible for up to USD 3,000 in rebates.Those who achieve savings above 20% will be entitled toaddition rebates.

"Increasing home energy efficiency impacts our country positively in multiple ways," said MikeLawrence, Johns Manville vice president and generalmanager for the Insulation Systems business.

Along with its nationwide network of professionalinstallers, Johns Manville also offers Formaldehyde-freeTM

insulation across America, as well as publishing informa-tion on other federal, state and local rebates, as well ashome energy audit tools, on its website.

Belgium's glass container mould manufacturer BMT Group hasannounced that it intends to set up a joint venture with Hindustan

National Glass & Industries (HNG), the largest glass manufacturer in India. BMT operates glass mould business through Omco International nv, and has glass mould shops in the UK, US, Belgium, Croatia, Austria, Istanbuland Romania.

Mukul Somany, joint managing director at HNG, confirmed the JV, saying:“We have had a few meetings and things are progressing well. Currently, we havefour plants making glass moulds.”

Jean-Christophe Seynaeve, director of BMT and managing director & CEO ofOmco, said: “We are in talks with HNG to set up a glass moulding shop in India.This will be a 50:50 joint venture and we are working on the various nuances ofthe venture at present.”

“The glass market in India is expanding and delivering glass moulds to itwould work very well. Shape of bottles and getting the right container in placeis hugely important now that a lot of big brands are being marketed in India.About 70% of the glass manufacturing in India is with HNG at present,”Seynaeve said.

The largest part of BMT's revenues come from the manufacture of industrialgears and transmissions, and the company is also exploring tie-ups with Indian gearcompanies.

“We are in the early stages of exploration for tie-ups and would talk to rail,gear and foundries to understand the Indian market. Our gear boxes, which aremanufactured with top class technology, are running in trains and metros,”Seynaeve said.

BMT also supplies a specific kind of a gear to Airbus and Boeing. “We havecontacts with HAL (Hindustan Aeronautics Limited) and we are talking on deliv-ering gears for their army helicopters,” he said.

BMTJOINT VENTURE

B&P NEWS GM 2_10 1-04-2010 10:32 Pagina 18

news& PRODUCTS

19

GERRESHEIMERFURTHER IMPROVEMENTS IN FINANCE STRUCTURE

Gerresheimer has further improved its financestructure over the past financial year. The compa-

ny’s equity ratio is at 35.8% (prior year 31.6%). Netfinancial debt was reduced by EUR 48.3 million to EUR373.3 million. Investment at the same time reached thehigh level of EUR 86.4 million.

Because of the decline in operating results and in orderto strengthen the financial base for future growth oppor-tunities, the Management Board and Supervisory Boardrecommends the Annual General Meeting that no dividendfor the financial year 2009 is paid. Gerresheimer does,however, intend to distribute attractive dividends again inthe future, depending on the success of business.

Gerresheimer is constantly widening its product portfo-lio, and, in financial year 2009, a third production line

was completed for prefillable syringes, production capaci-ty was built up for two insulin pen systems and invest-ments were made in new products in the field of diabetesdiagnostics.

Three new locations were established in three conti-nents. In China, a state-of-the-art plant was constructedfor pharmaceutical tubular glass. A new research anddevelopment centre for medical plastic systems wasopened in the US and a new production centre for pharma-ceutical plastic packaging in Spain. In Brazil, a new pro-duction facility for insulin pen systems is scheduled for2010.

While Gerresheimer expects growth for the pharmamarket, the outlook for cosmetics and Life ScienceResearch is more difficult. The Management Boardexpects for the current financial year a sales increase of 2-4% (in relation to adjusted sales excluding TechnicalPlastic Systems of EUR 970.8 million) and an improvedoperating margin (Adjusted EBITDA Margin) of around19.5%. Investment will total around EUR 75 million to80 million.

B&P NEWS GM 2_10 1-04-2010 10:32 Pagina 19

news& PRODUCTS


20

RIPPLE GLASSNEW GLASS RECYCLING VENTURE IN FULL SWING

Ripple Glass recycling plant, located inKansas City, Missouri, US, receives up to 20

tons of bottles per week. The company opened inNovember 2009, thanks to an idea from some of the orig-inators of the Boulevard Brewing Co., including presidentand founder John McDonald and chief financial officer JeffKrum.

“They looked at the 10 million bottles that they putout in the community, and that was only a drop in thebucket compared to the 150 million of all glass that endsup in area landfills,” Stelk said. “So they felt they want-ed to take responsibility for their product and help recycleall the other (bottles as well).”

Investors in Ripple include Boulevard Brewing Co. andUMB Bank.

“Prior to Ripple Glass, only 5% of the (Kansas Citymetro area's) glass was recycled,” executive director StaciaStelk said. “Since our launch, we have already seen anincrease in the amount of glass collected for recycling. Iexpect glass recycling to continue to grow.”

Ripple Glass has positioned recycling bins at morethan 60 locations across the area, and the bottles fromthese bins are sorted, cleaned, de-labelled and crushed bymachine. The resulting cullet (processed glass particlestiny enough to look like sand) is purchased by OwensCorning and remanufactured into fiberglass used in homeinsulation.

According to a company press release distributed inFebruary 2010, just one six-pack of beer bottles isenough to fill an entire wall cavity in a standard homewith fiberglass insulation.

“The timing is good because there is a heightenedawareness of environmental issues right now,” Stelk said,noting the extremely positive feedback from people whohave been participating thus far. “Even I was surprised athow excited people are to take their (glass for recycling).”

At present, the company only processes residentialglass beverage and food containers, but not dishes.However, according to Stelk: “Our next step is to addressbars and restaurants,” adding that 50% of glass wastecomes from places where people go out to eat or drink.

Stelk said she hoped that Ripple Glass would be ableto target bars and restaurants in the Kansas City area byearly summer, and that the company would post thenames of participating establishments on its website.

PEOPLE & CAREERS

BRITISH GLASSNEW CEO

APPOINTEDBritish Glass hasannounced that Dave Dalton

will become the CEO of the BritishGlass Manufacturers' Confederation,James Chisholm CFO and JohnStockdale will be promoted to theposition of environmental director.

These moves are seen as critical inresponse to meeting the diverse andchallenging needs of the glass indus-

try in these globally difficult eco-nomic times.

Following a reassessment of theneeds of the industry, the Counciland former director general DavidWorkman mutually agreed a way for-ward for the Confederation. As aresult, David Workman left BritishGlass at the end of February.

British Glass president, StephenPollock-Hill said, “The modern man-ufacturing trade association needs acomprehensive understanding ofissues and the restructuring of BritishGlass will enable the organization toservice the future needs of the glass

supply sector at national and interna-tional level.”

Speaking about the appointmentDalton said “I'm delighted to begiven the opportunity to build newlinks with industry and key stake-holders as we look to refocus ourefforts where they matter most, indelivering unrivalled quality of ser-vice, excellent representation andtangible benefits right across theglass community. The glass industryfaces many issues and I'm confidentthat we can meet those challengeswith the professional team of peoplethat we have here,”

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news& PRODUCTS


21

CLEANING MOULDS WITHULTRASOUNDS

Mould manufacturers and hol-low glass manufacturers now havea faster and more efficient methodof cleaning any kind of metalmoulds: cast iron, fully metallizedcast iron, steel, bronze-aluminiumof all types, and guarantees mouldintegrity for more than 80% of their average life cycle.

Ecotecne, the manufacturer of this ultrasonic cleaning equipment,has, in collaboration with Henkel, developed a proprietary system forhigh-cavitation, ultrasonic-assisted, chemical cleaning of glass moulds– the SC7 Light.

The cleaning process, which, says the Italian company, offers a fastermicro-cleaning/molecular process compared to traditional sand blastingsystems, is achieved by means of submersion in ultrasonic tanks thatcontain alkaline and acid solutions, powered by very strong cavitation.

The cleaning effect is a combination of both chemical and mechani-cal action, by means of the high-cavitation effect induced by piezoelec-tric-generated pulsing ultrasounds. The cleaning cycle involves immerg-ing the mould-loaded trolley into tanks according to a pre-regulated workcycle that includes alkaline pre-washing at about 85°C, acid treatment,alkaline with U/S treatment, and passivation, can be repeated every 15to 17 minutes, is controlled by a PLC, and exploits robot-controlledhandling systems.

The SC7 Light is compact, easy to use, versatile, economic and eco-logic, with a modular set up of less than eight metres in length, and canalso be equipped with shutters if needed, while manual lids are availableto close each single tank and prevent heat dissipation.

The cleaning effect is a combination of both chemical and mechani-cal action, and is caused by the high-cavitation effect induced by piezo-electric-generated pulsing ultrasounds, generated by two 4kW nominalpower units (with 8kW peak power) designed to achieve the maximum

cleaning efficiency with-out modifying the dimen-sions of the treated item.

The heating of thechemical water-based solu-tion in each tank is bymeans of electrical resis-tors, while the water usedfor intermediate rinsing isrecycled in a backsiderinse-and-skim tank.

All parts in direct con-tact with alkaline baths are

made of AISI 316 stainless steel; while tanks contain-ing acid solutions are made of polypropylene; otherparts are in AISI 304.

www.ecotecne.it

ULTRASOUNDS VERSUS SANDBLASTINGUltrasounds Sandblasting

1,800,000 bottles 800,000 bottles

Maintains brilliance and smooth Mechanically aggressive withflow of forming glass inside altered roughness of mouldsthe mould

Saving of raw material due tounchanged dimensions of themould cavity

B&P NEWS GM 2_10 1-04-2010 10:32 Pagina 21

news& PRODUCTS


22

STEUBEN GLASSLAYOFFS ANNOUNCED

Just over two years after Corning Inc. sold an80% stake in Steuben Glass to Schottenstein

Stores Corp. of Ohio, the prestigious art glass subsidiaryannounced 24 February 2010 that it is restructuring andwill begin laying off an undetermined number of employ-ees during the summer.

Steuben Glass's chief operating officer, Mark Samitt,said the plans were announced internally on 24 February.

"We will be going through a restructuring program thatwill allow Steuben Glass to appeal to a wider customerbase, provide quality products at a value and reposition thecompany to be profitable," Samitt said.

Included in the programme to be rolled out by mid-

summer is the outsourcing of some existing products thatwill mean the loss of some current manufacturing jobs atSteuben Glass.

Samitt said Steuben Glass employs about 100 work-ers. The number to be affected by layoffs will not beknown until later in the year.

Steuben Glass is working with Corning to provideopportunities for those who will lose their jobs. Like thehourly workers employed at Corning's manufacturingoperations, Steuben's hourly workers are represented bythe United Steelworkers of America Local 1000.

"We are planning to continue the plant operation andproduction in Corning after the restructuring, and CorningInc. is supportive of the effort," Samitt said.

Steuben Glass was sold in July 2008 because it lostUSD 30 million over a five-year period and did not fitwith Corning's high-tech industrial products portfolio.

Those money problems, Samittsaid, are apparently still at work.

"We looked at the market contrac-tion, and the recent sustained down-turn has had a significant negativeimpact. That is why we are takingthese steps to position us forgrowth," Samitt said.

Steuben Glass's crystal pieces aremanufactured at Corning Museumof Glass. Steuben also operates aretail store in Corning, as well ascustomer service, shipping andother functions.

Although the manufacturingoperation will be most affected bythe job cuts, Samitt said the compa-ny's strategy will "provide the bestpotential to compete and grow inthe crystal glass category, whileproviding value to the customers".

Steuben Glass was founded in1903 by T.G. Hawkes and managedby legendary British glassmakerFrederick Carder. It was acquired byCorning, then known as CorningGlass Works, during World War I.

Corning put the luxury crystaldivision up for sale in March 2008but retained a 20% stake in the spin-off company at Schottenstein'srequest because the Ohio companylacked the manufacturing experience.

Steuben Glass then became partof Schottenstein Luxury Group,which includes Judith Leiber pursesand the Italian fashion brand Shiro.

PEOPLE & CAREERS

GERRESHEIMERHERBERG LOOKS BACK OVER ALMOST

20 YEARS IN TOP MANAGEMENTAnnouncing that he is not seeking reappointment and will leave theManagement Board when his contract expires in June 2010, the CEO

of Gerresheimer AG, Dr. Axel Herberg, will hand over his job to UweRöhrhoff. At its february meeting, the Supervisory Board received this deci-sion with regret and appointed Röhrhoff as Management Board member.

Particularly in his ten years as CEO, Herberg has shaped the Düsseldorfcompany's development into an internationally leading supplier to the phar-ma and healthcare industry and was also instrumental in the successful flota-tion of Gerresheimer AG.

Röhrhoff has already been with Gerresheimer for 20 years. He was appoint-ed to the Management Board in 2003 and bore key responsibility for develop-ment of Gerresheimer's important US and Chinese business.

“The Supervisory Board is extremely sorry that Dr. Herberg is leaving theManagement Board. He has developed Gerresheimer into a very successfulglobal supplier for the pharma industry. The Supervisory Board thereforeunanimously recommends that Dr. Herberg is elected to this body. We arepleased to have Uwe Röhrhoff as the new CEO at the head of the businessfrom the summer. Mr. Röhrhoff is ideal for this position and, thanks to hisextraordinary specialist knowledge and industry expertise, enjoys a high levelof trust among employees and customers,” said Supervisory Board ChairmanGerhard Schulze.

Axel Herberg commented: “The Gerresheimer Group is excellently posi-tioned. The strategy to focus on pharma and healthcare with leading worldwidemarket positions has proven itself particularly during the crisis. With UweRöhrhoff, who I've worked with closely for almost 20 years, the company isin ideal hands." At the meeting, Hans-Jürgen Wiecha, who has been with thecompany for ten years, including five years on the Management Board, wasalso appointed as chief financial officer for a further five years.

B&P NEWS GM 2_10 1-04-2010 10:32 Pagina 22

ARDAGH GLASSRIGHT TO CHALLENGE PLANNING PERMISSIONSOUGHT

Ardagh Glass is reportedly seeking leave fromthe Administrative Court to challenge the deci-

sion of Cheshire West and Chester Council to grantQuinn Glass planning permission for its Elton plant.

The Court of Appeal recently dismissed Ardagh's chal-lenge to the High Court's confirmation of the council'sright to grant retrospective planning permission forQuinn's plant - if there were exceptional circumstances fordoing so.

Council leader Mike Jones said: “The council hasworked closely with the London office of specialist law

firm Denton Wilde Sapte in successfully defending itsposition and will continue to do so in respect of this la-test challenge. In light of the Court of Appeal decision,we remain confident that our approach to this matter hasbeen entirely correct throughout and remains so in respectof this latest challenge.”

The council granted planning permission for the Quinnplant in November 2009 as it had always believed that itwas entitled to decide the matter.

During the recent hearing at the Court of Appeal,judges ruled that if taken to their logical conclusion, thelegal arguments put forward by Ardagh's leading barris-ter would mean that a planning authority could nevergrant permission for an existing development even if theenvironmental effects of the development were positive.

The court reached a unanimous decision on the firstday without hearing Quinn Glass or the council and dis-missed the appeal.

Ardagh Glass was also ordered to pay the council'scosts in responding to the appeal and was criticized for the unnecessary amount of paperwork filed in support of its case. Moreover, the court also refused togrant Ardagh permission to appeal to the Supreme Courtin the UK or to refer the matter to the European Courtof Justice.

news& PRODUCTS


23

PPGNORTH CAROLINA

FIBERGLASS FURNACERESTARTED

PPG Industries' fiberglass businessannounced 23 February 2010 that it has

restarted a furnace at its facility in Lexington, NorthCarolina. The furnace was restarted to supportincreased demand, particularly in the wind energy andfiltration markets, and it is expected to restore about21,000 metric tons of annual capacity at the plant."The restart of the second furnace at Lexington helpsposition PPG to support increasing demand for fiber-glass as the economy returns," said KevinMcDonald, PPG gene-ral manager, fiberglass rein-forcements, Americas and Europe. "This actiondemonstrates PPG's commitment to the fiberglassindustry and to manufacturing products that meetcustomers' needs in various markets."

The Lexington plant has added 180 employees tosupport the furnace restart, some of which wererecalled from layoffs.

Dura Temp, a leading supplier in hot warehandling solutions, has been appointed as the

global distributor for Protatherm® hot ware han-dling products in many markets around the world.Complimenting Dura Temp’s line of hot ware han-dling solutions, Protatherm® will add gob funnels,gob deflector plates, mould top plates, takeoutinserts, deadplates, transfer plates, and other items tothe company’s current line of products. TheProtatherm® range of products and materials havebeen specifically designed to aid in the forming andhandling of hot glass containers in production.

This new partnership between Dura Temp andProtatherm® offers customers one point of contact forall of their hot ware handling needs from gob deflec-tors through the lehr loader.

Since 1983, Dura Temp Corporation has provid-ed the glass industry with superior hot glass han-dling materials and quick-change parts and assem-blies, providing a variety of ware handling solutionsfor container glass, tableware, and bending and tempering.

Dura Temp’s range of high temperature materialsand products, says the US company, virtually elimi-nate damage to glass on account of thermal stress, oilabsorption, and abrasion.

DURA TEMPGLOBAL DISTRXIBUTOR

FOR PROTATHERM®

B&P NEWS GM 2_10 1-04-2010 10:32 Pagina 23

INTERVIEW

Emhart Glass:

SPEAKING TO THE SPECIALISTS– with perfection in mind


Inte

rvie

w

Emhart art GM 2_10 1-04-2010 10:42 Pagina 24

lass MachineryPlants & Accessories– GMP&A

At present, the con-tainer industry is striving to findnew uses and applications forglass, which also involves complexglass types and, obviously, specificmachinery to deal with them. Whatis Emhart Glass doing to respondto these requests for inspection andquality with regards to health andsafety standards too, of course?

Martin Jetter – President of Emhart Glass

In terms of container quality, themarket requires a continuousimprovement of the inspectiontechnology, which we are providingwith our new FleXinspect machineportfolio and our MiniLab. Theseproduct lines are offering a numberof improved inspection methods,both, online and offline. But quali-ty should not only be measured, itmust be produced first. And in this

regard we are continuously improv-ing products and processes in ourResearch Center in Windsor,Connecticut, United States. Theproduct launches, which we plan for2010, will be an important stepinto this direction.

Besides improvement of existingprocesses, we are also looking forcompletely new innovations: wewill soon launch a method to sig-nificantly improve the quality ofglass in terms of its properties.With our new Hardglass technolo-gy, which is at the moment devel-oped and tested in our ResearchCenter, we are able to improve thestrength of a container significant-ly, which offers new applications,

Many developments have

been and are still taking

place in the glass industry,

especially with regards to the

hollow – or container – glass

sector. Companies need to

be ‘top of the class’ to stand

out from their competitors

and Glass Machinery Plants

& Accessories decided, with

this interview-style article, to

give its readers an idea of

what goes on inside one of

the world’s leading

machinery manufacturers –

Emhart Glass.

glass machinery plants & accessories 2/2010 25

GMartin Jetter President of Emhart Glass

Fig. 1 - NIS 12 SectionTriple Gob


and, in addition, makes glass moreattractive in comparison with com-petitive packaging materials.

In addition, we also recognize anincreasing interest in health issues,which is a trend, that helps glassover other packaging materials suchas PET or cans. Emhart Glass rec-ognizes its responsibility in aworld, which shows a high sensi-bility for health aspects, and there-fore we have hired a scientist, spe-cialized in toxicology and environ-ment, looking into these issuesfrom a strictly scientific aspect.This will help the whole glassindustry against the competition ofother packaging materials, but italso helps to identify possible areasof improvement for glass.

GMP&AMany glassmakers are, despite

the global crisis, investing in spe-cialization. How does EmhartGlass consider the continuousrequest for return on investment(ROI)?

Martin JetterOur mission statement states that we

will support our customers in their quest forsustainable profitability, quality andincreased market share through automationsolutions. This is the guideline for our dailydevelopments and efforts. It was the reasonfor the investment in our Research Centerin Windsor, where we develop new process-es and equipment, which allow higher qual-ity and efficiency. Many of those new prod-ucts will be presented at glasstec 2010.

Inte

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wINTERVIEW

Emhart Glass invested EUR 18 million in its research centre in Windsor,Connecticut, United States, which covers 27,500 sq.ft., with a further 18,000sq.ft. office space.The centre is equipped with a complete production line for the manufactu-re of glass bottles, including a 40 tonnes/day, oxy-fuel fired furnace (desi-gned by Sorg with refractories from RHI and PDR); the capability for twoforehearths, although only one – a joint Emhart/Sorg 240 type forehearth - iscurrently in operation. The feeder and shear are Emhart Glass equipmentbased on its 555 feeder.The cross conveyor and stacker were supplied by Sheppee International,while the gas fired lehr – 2 x 23 metres – is from EW Bowman. The cold end

conveyor is from German supplier DMA andinspection is managed by Emhart Glass’Veritas family of inspection machines.This is not the first time that Emhart Glass hasbuilt such a facility. During 1929 – 1964 it ope-rated a research centre in Hartford,Connecticut with three furnaces and a totalcapacity of 40 tonnes/day melting capacity.

Emhart Glass

RESEARCH CENTRE

Fig. 2 - Research Center Windsor

Fig. 3 - Research Center Cold End

Fig. 4 - Research Center Hot End

Figure 3

Figure 4

Figure 2



But we do not only offer “hard-ware” products to support the ROIof our customers. We have built asupport team including glass pro-duction experts, which are support-ing our customers to increase effi-ciency and quality in their opera-tions. In 2009 we launched a num-ber of service products like produc-tion assistance, mold coolinganalysis, mold design, containerproperty analysis, TechnicalAssistance Agreements, or remoteservices.

GMP&AWhat can you tell us about

Emhart Glass’s new – or as youcall it - next generation - ofinspection systems – FleXinspect?

Jeff Hartung – Vice President,Inspection

The FleXinspect product familyis the direct result of the talents andtechnical strengths which resultedfrom the successful integration ofthe ICS/Inex engineering compe-tencies and talent with the engineer-ing competencies and talent ofEmhart Glass – using only the bestof the best. This technical team pro-vided the FleXinspect platform andproduct family based on direct feed-back from the market and closedevelopment cooperation with ourcustomers. The machines providethe customer with the reliabilitythey all seek: reliable inspections,reliable electro/mechanical systems,reliable and simple Human Interfaceand Statistics Reporting. In addi-

Figure 5

Figure 6

Figure 7

Fig. 5 - MiniLab

Fig. 6 - MiniLab MLP

Fig. 7 - MiniLab line



tion, the product family providesthe customer with the flexibilitythey need to configure their ColdEnd in such a way that their strate-gy for the future is supported now,as well as in the future – by justadding capabilities to the existingplatforms. In short, theFleXinspect is a technology plat-form that reliably suits the needs oftoday – with the capability to adaptto and apply technological advanceswithout major Cold End equipmentand layout changes. TheFleXinspect family consists of:FleXinspect T, FleXinspect BC, andthe FleXinspect M. TheFleXinspect T is a vision enabledrotary handler that can be configuredas a Total Inspection Solution. TheFleXinspect BC capitalizes on theadvances in camera and servo tech-nology to provide more reliable andeasy to use vision based inspec-tions. The FleXinspect M is a lowcost fixed functionality solutionthat fits the footprint of existinglegacy line footprints of installedbase machines without changinglayouts, just slide into place wherethe old machine existed.

GMP&AWhich global market areas

are these different solutions indi-cated for?

Do these various possibilitiesmean that FleXinspect is so modu-lar it can grow with the request andproduction of the glassmaker?

Jeff HartungThere are many drivers that

influence the needs of our cus-tomers when deciding on how to

invest and configure their cold end.These drivers vary in importancedepending on the specific situation.In many existing plants real estateis an issue as the cold end is shrink-ing; container quality levels anddemands are increasing with pricesdecreasing; and investment in thehot end in order to improve their

Inte

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Jeff HartungVice President, Inspection

FIG. 8 - FleXinspect BC

EMHART GLASS TIMELINE1902 The idea: The story begins with an idea shared by US entrepreneurs

Karl E. Peiler, William H. Honiss and William A. Lorenz: to find new waysof making and using glass containers.

1912 Founded in Hartford, Connecticut: Four more businessmen join to form theHartford-Fairmont Company, which develops the first glass gob shearingand feeding device, the forerunner of modern glass container machines.

1913 Hartford-Fairmont introduces the first plunger-feeder, laying the founda-tions for the automation of the glass container industry.

1922 Hartford-Fairmont joins with the Empire Machine Company to formHartford-Empire.

1924 Patent of IS Machine: Glassmaking pioneer Henry W. Ingle creates thefirst individual section (IS) machine, a new automation standard that stillforms the core of our product range.

1925 The first four IS machines go into operation, heralding the dawn of auto-matic container manufacturing.

1932 Hartford-Empire introduces a continuously rotating paste-mould machi-ne, allowing glassmakers to manufacture seamless tableware.

1940 The first double-gob equipment is introduced.

1945 The HE-74 check inspector is introduced, and inspection research ismade a priority.

1951 A new name, ‘Emhart Manufacturing Company’, reflects an ambition toexplore new directions.

1952 European Manufacturing: Emhart Glass makes its first move overseasby acquiring Aktiebolaget Sundsvalls Verkstader in Sweden.

1954 The first six-section IS machine is introduced, along with the HE-127automatic finish check inspector.

1968 The first triple-gob machine is introduced.

1970 The first eight-section double-gob machine hits the market, delivering a30% improvement in productivity.

1972 A ten-section double-gob machine with modular sections is introduced.

1974 Emhart Glass ships its 1000th IS machine and launches its innovative516 electronic control system.



complement of inspections availableto the “invest in the basic platform”and build over time through opera-tional investments as their inspec-tion needs change. The machines aretruly modular allowing customers todecide on how and where to inspectfor certain defects – as well as pro-vide them with the option for redun-dant inspections. In addition, we pro-vide a solution for the customer whohas a large installed base but is notready for a full cold-end rebuild. Weinclude in the product family a mod-ern low cost, fixed functionalityproduct that fits into their existinglayouts and legacy footprints whilereplacing their old technology withreliable new technology.

GMP&AHow does Emhart Glass decide

which FleXinspect is right for eachclient?

Jeff HartungReally it is a matter of sitting

with the customer and workingthrough the details that derive fromtheir overall investment strategy inhot end, combined with their coldend strategy for the demands of theircustomer’s specifications, and allthe other constraints that may exist– financial, speed, real estate, tech-nical, personnel, etc. For sure, therehas been a paradigm shift in theInspection Business of EmhartGlass. We no longer supply onlyinspection machines. We supplyautomated solutions and servicesupport. This new way of workingresults in the best solutions for ourcustomers: working directly togeth-er to get the best solutions onpaper, ideally between EmhartGlass product specialists and cus-tomer cold end technical teams. Inaddition the introduction of ProjectManagement to the InspectionBusiness of Emhart Glass and AfterSales Service products allow thecustomer to have full supportbefore during and after their invest-ment decision. The proper selectionof equipment, or optimal path for

FIG. 9 - FleXinspect T

1977 The first Advanced IS machine AIS is installed.

1980 Emhart Glass’ first Total Machine AIDA (Automatic Inspection DefectAnalysis) is demonstrated.

1982 Emhart Glass acquires Powers Manufacturing Inc., based in Elmira, NY.Powers had established an international reputation for quality cold-endinspection equipment, and its facility was ideally suited for producingEmhart Glass’ Total Inspection Machines TIM.

1985 The VertiFlow mould cooling system is introduced, almost doubling pro-duction speed and enhancing product quality and strength.

1986 Emhart Glass introduces its Flex-line system, allowing glass producersto make rapid changes to the number of IS sections being used.

1989 Emhart Glass is acquired by The Black & Decker Corporation.

1990 Emhart Glass launches innovations including servo-electric parallelshears, an improved 555 servo-electric feeder system, the T600 LANforming control system, the 560 servo-electric pusher and pocket air fin-gers for pusher mechanisms.

1998 Emhart Glass is acquired by Bucher Industries of Niederweningen,Switzerland.

1999 Emhart Glass’ first NIS starts operation at WiegandGlas.

2000 The Next Generation IS machine NIS is introduced, delivering up to 4.2per cent higher cycle rates, reducing workout times by half and increa-sing mould life by up to 20 per cent.

2002 Introduction of the Veritas series of inspection machines.

2004 FlexISProcess Control is introduced to the market.

2005 NIS becomes available in a quad-gob configuration.

2007 Emhart Glass completes the acquisition of ICS Inex Inspection Systems.Established in 1855, Inex created Optitron, the first inspection machinefor refillable bottles, in 1955, and subsequently built a strong position ininspection devices for the pharmaceutical, food and general packagingindustries.

2008 Opening of the Emhart Glass Research Center in Windsor Connecticut(see separate text box on page 26).

2009 Opening of new plant in JohorBahru, Malaysia, for the production ofglass container forming products.

efficiencies and produce higher quali-ty containers faster. These are just afew of many. The FleXinspectallows the customer to review

their strategies for containers,production speeds, specificationand quality demands etc. thenselect an optimal solution ofconfigured FleXinspect. Butmost important is that invest-ment decision can be built

upon, through oper-ational investments– increasing inspec-tion capabilities

without changing theplatform. Many conceptsregarding flexibility wentinto the design ofFleXinspect. This product

family provides the customerwith different investment options:from the “get it all at once” invest-ment decision - providing the full



the customer, will ultimately derivefrom this close cooperation withthem. Working together we helpour customers be more competitiveand profitable.

GMP&ABeing the top of the range, which

glassmakers is FleXinspect T suit-able for?

Jeff HartungReally it is matter of customer

philosophy. Each customer has a dif-ferent way of doing things and/or dif-ferent preferences. It is very impor-tant that Emhart Glass truly under-stands what the customer is trying toaccomplish so that we can providethem with the best solution. Thereare so many drivers affecting thisoutcome that the best way to answeris through understanding the cus-tomer’s immediate and long termneeds and strategy. The FleXinspectT is a suitable solution for cus-tomers with real estate issues andfurther need to combine inspectionsinto one machine. This machine canbe a total inspection solution formany of today’s containers.However, this really is dependent onthe customer’s preference/philoso-phy and container portfolio and qual-ity requirements. In addition, the

FleXinspect T reaches the customerwho wants to start advancing but notquite ready to invest in a full com-plement of machines. TheFleXinspect T allows them tomigrate from traditional inspectionsto those traditional inspections withmore advanced technology plusincreasing their capabilities step-by-step. Really the FleXinspect T issuitable for most of the market needsbut for the extreme price sensitivecustomers who don’t desire the needfor the potential of building on thismodular platform – we offer a lowcost fixed functionality solution:The FleXinspect M.

GMP&AHow does the client – or how

does Emhart Glass discuss with theclient about the features ofFleXinspect T and how and when toupgrade it?

Jeff HartungTypically the need derives from

an additional requirement from ourcustomer’s customer, or increase inproduction speeds in the hot end.But in some cases our customer’smay have a need to increase theirinspection capabilities in order toprovide the necessary informationfeedback to assist the hot end with

improving their quality. Anotherfactor is the addition of a new con-tainer, which requires differentinspection methods, or an increaseto the number of inspection sta-tions so that the container can befully inspected. Also we must notforget, advances in technology andinspection algorithms may be ofinterest to the customer. Becausethey have invested in thisFleXinspect platform, they havethe choice to add these capabilitieswithout investing in additionalequipment. In addition, our productspecialists and service audits mayresult in recommendations to thecustomer that improve their con-tainer inspections, or yields, withX, Y or Z upgrades.

GMP&AAt the Glassman Middle East

show in November 2009, EmhartGlass presented its numerous ISmachines, along with the glass con-tainer industry situation and dri-vers. How do you advise yourclients on which production andquantities?

Martin JetterAt Glassman we showed the

solution for lowest investmentwithout compromising the quality.It is our SIS machine, which ishighly recognized by the market. Inthe short time since its launch wehave shipped already 22 machinesof this type! On the other hand we

Inte

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wINTERVIEW

Locations:Cham, Switzerland (Head Office)Clearwater, Florida, USA (Sales, Marketing & Research)Windsor, Connecticut, USA (Research Center)Elmira, New York, USA (Manufacturing & Logistics)Owensville, Missouri, USA (Manufacturing, Logistics & Sales)Singapore (Sales office)Johor Bahru, Malaysia (Manufacturing, Logistics & Training)Kawasaki, Japan (Sales office)Manchester, United Kingdom (Sales & Service)Sundsvall, Sweden (Manufacturing, Logistics & Training)Örebro, Sweden (Manufacturing & Logistics)Madrid, Spain (Sales, Service & Training)Moscow, Russia (Sales office)Dego, Italy (Logistics, Manufacturing & Sales)Neuss, Germany (Sales office)

Emhart Glass

GENERAL FACTS AND FIGURES

Figure 10



have the unbeatable solution forlowest container cost and flexibili-ty, which is our NIS machine. OurIS and AIS machines are in betweenthese two positions. We are analyz-ing with our clients their specificsituation regarding available invest-ment, container mix and volume,

and then propose and offer the bestsolution for every specific demand.

GMP&AWhat about Emhart Glass’s

other machinery? – ware transfer,cooling, forming, plunger processcontrol, flex pressure system,

FlexIS process control system,refractories, etc., sampling, – youseem to be right on track to givetotal control and managing in manufacturing processes!

Martin JetterCorrect, Emhart Glass has the

most complete product portfolio inthe glass container industry, includ-ing gob forming, container form-ing, handling, online inspection,offline inspection services and pro-duction support. This allows addi-tional customer benefits. Oneexample: all hot-end functions areintegrated in our control systemFlexIS. One job database, onealarm database, one production per-formance database, one maintenanceplatform, one remote access plat-form for the whole line! This is amajor progress for the benefit ofour customers. In addition we offernow remote access services. Ourexperts can look into the controlsystem online and not only identifyproblems, but also wrong settingsor potential for production

Figure 11

Fig. 10 - NIS Quad Gob

Fig. 11 - NIS with FleXPusher

Fig. 12 - NIS Triple Gob

Fig. 13 - FleXPusher

Figure 12

Figure 13



Inte

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improvements. All is possiblebecause we control the whole chain.

In the future we plan to go onestep further: we will use the capa-bility of “total control” to closethe loop: automatic parameter set-ting and tuning based on the mea-surements of various sensors andmeasuring equipment. First closedloop solutions will be shown atglasstec 2010.

GMP&AAny further developments

planned? Which?

Martin Jetter2010 will be a record year in

terms of new product launch. Twoyears after the start up of ourResearch Center, which includes afull functional glass productionpilot line, we are now able to showthe results of our increased invest-ment in Research, Development andEngineering. All products that wewill be launching in 2010 and pre-senting at glasstec, will target on

increased productivity, higher speedand efficiency, and improved quality.This is in line with the commit-ment of our mission statement.

GMP&AAnd what are the future prospects

for expansion at Emhart Glass – youare already present in the UnitedStates, Asia and Europe, but will yoube considering further branches inother precise countries – where?

Martin JetterWe are globally present already

today. In addition we strengthenedour presence in East Europe by theopening of our Moscow office twoyears ago. In 2010 we will strength-en our presence in the Middle East.

But we will also strengthen ournetwork with other leading suppli-

ers of the industry. In December2009 we founded the GlassAlliance, a cooperation of leadingglobal players Zippe, Horn, Emhart

Glass and MSK. These companieswill cooperate intensively to pro-vide “total solutions” in terms ofproducts, services, engineering andfinancing for customer projects,including turnkey projects. Ofcourse we will also utilize mutual-ly our sales networks, whichstrengthen the presence of all part-ners of the alliance. ■

EMHART GLASS MANAGEMENTMartin Jetter President

Jeff Hartung Vice President Inspection

Bertil Bjugard Vice President Logistics & Manufacturing

Edward Munz Vice President Corporate Development

Franco Venturelli Vice President Sales & Marketing

Steven Pinkerton Vice President RD & E

William Grüninger Vice President Technical Services

N. L.Wong Vice President Finance

Ian Green Director Product Management

PERCENTAGE OF GROWTH 2004-2008

HOT ENDEmhart, NIS, AIS, SIS, VertiFlow,InVertiFlow, Flex, FlexIS, FlexLine,FlexVector, FlexPusher, FlexReport,FlexPressure, FlexVectorDrive, Versa-Cam,23, 191, 200, 210, 535, 555, 565, VLAN,T300, T600, T6000, SETO, FPS, H28COLD ENDEmhart, INEX, Powers, ProScanner,Scanner, QualiTrac, TIM, Veritas, ICS,SuperScan, SuperVision, ProLaser, SmartPass, QuantaView, ChromaView, Gemini,MiniLab, FleXinspectCOMPANY VISION AND MISSION• Vision - Our vision is a world with glass

as a dominant and preferred ecologi-cal packaging material, enabled byEmhart Glass as the leading techno-logy provider.

• Mission - We support our customersin their quest for a sustainable profita-bility, quality and increased marketshare in the packaging industry throu-gh our automation solutions.

PRESENCE AT TRADE FAIRS IN 2010Glassman São Paulo 2010Mir Stekla 2010glasstec 2010

Registered trademarks

HEADCOUNTDecember 2009:

RD&E 75

Sales & Marketing 73

Manufacturing 538

Technical Services 89

Infrastructure 100

Total 875

EMHART GLASS S.A.

Hinterbergstrasse 22 - PO Box 2251Ch-6330 Cham 2 - SwitzerlandTel: +41 – 41 – 7494200Fax: +41 – 41 – 7494271E-mail: [email protected]

www.emhartglass.com


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CCOOPPYY DDAATTEE:: EEnndd ooff AApprriill 22001100 PPUUBBLLIICCAATTIIOONN DDAATTEE:: JJuunnee 22001100

LASSWARE INDUSTRWORLD

DIRECTORY 2010LASSWARE INDUSTR

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DIRECTORY 2010

…the most complete companyprofiles of suppliers and glassworks worldwide!

PROMOTE YOUR COMPANY WORLDWIDE❶ ❷ ❸ ❹SUPPLIER LISTINGS INCLUDE:

• Address • Company Officers• Parent Company• Sister Companies (Domestic/foreign)• Plants (Domestic/foreign) • Number of employees • Annual Turnover (Group/Company)• Nominal Capital • Year Company founded • Banks • Planned Exhibitions

• Registered Trademarks (products)Membership of Associations

• Areas of Activity • New Products, innovations • Photo(s) • Company logo/trademark • Percentage of turnover from glass • Sales (domestic/foreign) • Quality Certifications • Occupied Area in sq. m.• Registered patents

ALPHABETICAL LIST OF SUPPLIERS TO THE GLASS INDUSTRY WITH FULL PAGE COLOUR PROFILES

GIVING THE MOST COMPLETE REVIEW OF EACH COMPANY:

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• Raw Materials: Handling and Preparation • Melting • Refractories • Moulds: Alloys, Parts, Processing • Lubricating • Forming • Cooling • Annealing and Toughening • Processing • Decorating • Cold-End/Packaging • Plant Utilities • Engineering Companies • Consultants

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FREE LINK FROM GLASSONLINE YELLOW PAGES

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GLASSO

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OM

21ST ANNUALEDITION

WGID 10 Pubbl 30-03-2010 9:17 Pagina 1

Letter for Company Name ................................................................................................................................................................................. alphabetical index Address (❑ HEADQUARTERS, ❑ BRANCH, ❑ PLANT) .................................................................................................................................................................................................

Postal code ................................................ City ................................................................................ Country .......................................................................................

Tel. int.: + .................. /area code: ...................... /.................................................... ; Fax int.: + .................. /area code: ..................... /....................................................

E-mail .................................................................................................................... www. .......................................................................................................................................

Plant Name .................................................................................................................

Address .........................................................................................................................

Postal code ...................................... City ...............................................................

Country .........................................................................................................................

Tel. int.: + ................../area code: ...................... /.....................................................

Fax int.: + ................../area code: ...................... /.....................................................

Plant Manager ..........................................................................................................

Number of employees at plant ........................................................................

Number of furnaces: ........................... tons/day (total): ..........................

Fuel used ......................................................................................................................

MACHINES/EQUIPMENT: NAME OF

Type: ............................................................ Supplier: ..........................................

Type: ............................................................ Supplier: ..........................................

Type: ............................................................ Supplier: ..........................................

PLANT PRODUCTION:..................................................................... ....................................................................

..................................................................... ....................................................................

..................................................................... ....................................................................

Export: ❑ YES ❑ NO

Plant Name .................................................................................................................

Address .........................................................................................................................

Postal code ...................................... City ...............................................................

Country .........................................................................................................................

Tel. int.: + ................../area code: ...................... /.....................................................

Fax int.: + ................../area code: ...................... /.....................................................

Plant Manager ..........................................................................................................

Number of employees at plant ........................................................................

Number of furnaces: ........................... tons/day (total): ..........................

Fuel used ......................................................................................................................

MACHINES/EQUIPMENT: NAME OF

Type: ............................................................ Supplier: ..........................................

Type: ............................................................ Supplier: ..........................................

Type: ............................................................ Supplier: ..........................................

PLANT PRODUCTION:..................................................................... ....................................................................

..................................................................... ....................................................................

..................................................................... ....................................................................

Export: ❑ YES ❑ NO

FREE LISTING FOR GLASSWORKS - 1

Name .......................................................................................................................... Job Title .............................................................................................................................

Name .......................................................................................................................... Job Title .............................................................................................................................

BBaannkkss::Name .............................................................................................................................

Name ..............................................................................................................................

MMeemmbbeerr ooff ((AAssssoocciiaattiioonnss))::..........................................................................................................................................

..........................................................................................................................................

For the ”World Glassware Industry Directory 2010“ - Free listing for Glassworks - page 1/2

.........

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N.B. This form is ONLY for glassworks. Suppliers of machinery, equipment, accessories etc. to the glassindustry have to turn to pages 31-33, starting from the opposite cover.

…please complete

the 2 forms and fax them

to Artenergy Publishing, no later

than April 2010.

Fax: +39 02 66305510

CCoommppaannyy OOffffiicceerrss

NNuummbbeerr ooff pprroodduuccttiioonn ppllaannttss:: ❑❑ ddoommeessttiicc nnoo.. ....................... // ❑❑ aabbrrooaadd nnoo.. .......................

AAnnnnuuaall ttuurrnnoovveerr:: € ..................................................; US$ ....................................................

NNoommiinnaall ccaappiittaall:: € ................................................; US$ .....................................................

QQuuaalliittyy cceerrttiiffiiccaattiioonnss:: .............................................................................................................

NNuummbbeerr ooff eemmppllooyyeeeess:: ..............................

CCoommppaannyy ffoouunnddeedd:: year ..........................

TTuurrnnoovveerr ffrroomm ggllaassss:: ..........................................%

PPaarreenntt ccoommppaannyy:: ..............................................................................................................................................................................................................................................

SSiisstteerr ccoommppaannyy//iieess:: .......................................................................................................................................................................................................................................

....................................................................................................................................................................................................................................................................................................

....................................................................................................................................................................................................................................................................................................

Vetrerie GM 2010 N+G 1-04-2010 10:45 Pagina 1

CCoommppaannyy’’ss iinnddeexx ooff pprroodduuccttss::

❏ AEROSOLS❏ BEER❏ COSMETICS❏ DRUG, PHARMAC.❏ FOOD❏ FRUIT JUICE❏ MEDICAL❏ OLIVE OIL❏ PERFUME❏ SOFT DRINKS❏ SPIRITS❏ VACUUM BOTTLES❏ WATER ❏ WINE❏ OTHERS (PLEASE SPECIFY)

........................................CAPACITY/SHAPEFrom ............... ml.up to ............... ml.❏ Narrow neck❏ Wide mouth

❏ PRIMARY GLASS MANUFACTURER❏ SECONDARY GLASS MANUFACTURER❏ WITH DECORATING LINE❏ DECORATOR ONLY

MADE OF:❏ CRYSTAL

❏ LEAD CRYSTAL

❏ FULL LEAD CRYSTAL

❏ SODA LIME

❏ BOROSILICATE

❏ OPAL

❏ OTHERS (PLEASE SPECIFY)

................................

................................PRODUCTIONTECHNIQUES

❏ HANDMADE

❏ MACHINE-MADE

❏ SEMI-AUTOMATIC

❏ PRESSEDWARE

❏ INJECTION

❏ MOULDS, IN HOUSE

❏ OTHERS (PLEASE SPECIFY) ❏ OTHERS (PLEASE SPECIFY)

..............................................................................

..............................................................................


❏ TUBING❏ VIALS❏ AMPOULES


❏ BOWLS❏ BULB ENVELOPES❏ BULBS, MINIATURES❏ BULBS, QUARTZ❏ CHANDELIERS❏ CHANDELIER TRIMMINGS❏ CHRISTMAS ORNAMENTS❏ LAMPSHADES❏ LAMP-CHIMNEY ❏ LAMP ENVELOPES (INCANDESCENT)❏ LAMP ENVELOPES (FLUORESCENT)❏ LAMP ENVELOPES (HALOGEN)❏ LENSES❏ REFLECTORS❏ TUBES (FLUORESCENT)❏ TUBES (QUARTZ)❏ OTHERS (PLEASE SPECIFY)

..............................................................................

..............................................................................


❏ BEADS❏ BLOCKS OR BRICKS❏ CATHODE-RAY TUBES❏ ELECTRICAL INSULATORS❏ ELECTRONIC COMPONENTS❏ GLASS-TO-METAL SEALS❏ PIPING AND FITTINGS❏ PRECISION BORE❏ RODS❏ TILES❏ TUBES❏ VACUUM WARE❏ OTHERS (PLEASE SPECIFY)

..............................................................................

..............................................................................❏ PRIMARY GLASS MANUFACTURER❏ SECONDARY GLASS MANUFACTURER❏ WITH DECORATING LINE❏ DECORATOR ONLY

❏ APPARATUS

❏ BEAKERS❏ BOTTLES AND JARS❏ CAPILLARY TUBES❏ CHEMICAL (GENERAL)❏ DEWAR FLASKS❏ LABORATORY (GENERAL)❏ MEDICAL GLASSWARE❏ PIPETTES❏ SCIENTIFIC (GENERAL)❏ TEST TUBES❏ THERMOMETERS❏ TUBES❏ VOLUMETRIC GLASSWARE❏ OTHERS (PLEASE SPECIFY)

..............................................................................

..............................................................................


❏ LAMP BULBS❏ LENSES (HEADLIGHTS)❏ REFLECTORS❏ SEALED BEAM UNITS❏ SIGNAL DOMES❏ OTHERS (PLEASE SPECIFY)

..............................................................................

..............................................................................

❏ PRIMARY GLASS MANUFACTURER❏ SECONDARY GLASS MANUFACTURER

..............................................................................

..............................................................................

..............................................................................

..............................................................................

..............................................................................

..............................................................................

..............................................................................

DATE ...............................................NAME......................................................................................................................................................................

STAMP ANDJOB TITLE................................................................................ SIGNATURE ..............................................................................................................

PPlleeaassee ffiillll iinn ffoorrmmss ❶ -- ❷ aanndd ffaaxx tthheemm ttoo uuss (+39 - 02 - 66305510) nnoo llaatteerr tthhaann AApprriill 22001100..

PLEASE ALSO ATTACH

YOUR COMPANY LOGO

IT WILL BE PUBLISHED

FREE-OF-CHARGE

Company Name .......................................................................................................................................................................................................................................................

FREE LISTING FOR GLASSWORKS - 2

For the “World Glassware Industry Directory 2010“ - Free listing for Glassworks - page 2/2

COLOURS:❏ ANTIQUE

❏ BLACK

❏ BLUE

❏ BROWN

❏ DARK GREEN

❏ HALF GREEN

❏ HALF WHITE

❏ LIGHT GREEN

❏ OPAL

❏ WHITE

❏ YELLOW


.................................PRODUCTIONTECHNOLOGY❏ HANDMADE

❏ MACHINE-MADE

❏ SEMI-AUTOMATIC

❏ MOULDS, IN HOUSE


.................................

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1. BOTTLES AND CONTAINERS

2. DOMESTIC GLASSWARE

5. TECHNICAL, TV AND INDUSTRIAL GLASSWARE

4. LIGHTING GLASSWARE

3. TUBING, VIALS AND AMPOULES 6. SCIENTIFIC, LABORATORY AND MEDICAL GLASSWARE

7. AUTOMOTIVE GLASSWARE

8. OTHER PRODUCTS

❏ ARTWARE❏ ASHTRAYS❏ BARWARE/RESTAURANT❏ BOWLS❏ COOKWARE❏ DECANTERS❏ DRINKING GLASSES❏ GIFTWARE❏ JUGS❏ KITCHENWARE❏ JEWELLERY❏ MUGS❏ ORNAMENTAL❏ STEMWARE❏ TABLEWARE❏ TUMBLERS❏ VASES

Vetrerie GM 2010 N+G 1-04-2010 10:45 Pagina 3

he cornerstone of what isHorn Glass Industries AGtoday was laid over 100years ago, when August

Horn founded a small glass serviceindustry in Bavaria in 1894. HornGlass Industries AG has carried thistradition further to join the ranks of

leading international glass plantequipment manufacturers.

Today Horn is, for example,placed amongst the Top 500 ofEurope’s Job creating companies bythe Europe’s Award and employsover 180 people.

Horn’s range includes forehearth

systems, supply stations for oil,gas, oxygen, water, regenerative andrecuperative burner systems of thehighest standard. Horn GlassIndustries AG also offers combus-tion systems, control and safetyequipment, electric boosting andcolouring systems, to name but a

HOT-END EQUIPMENT

Horn Glass Industries:

COMPLETE ANDCOMPREHENSIVE

ENGINEERING for the glass industry


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Horn art GM 2_10 26-03-2010 12:53 Pagina 36

few. Horn has developed productssuch as the Optibeam; the interna-tionally acclaimed laser glass levelcontrol system.

A further product sector ismachinery for the thermal process-ing of glass as roller annealing anddecorations lehrs, as well as hot-and cold-end coating stations andmuch more.

FURNACE ENGINEERINGAND MODELLINGEngineering Service - Project Management

Horn Glass Industries AG offerscomplete comprehensive and pro-fessional designs for melting end,working end, forehearths and other

peripheral plants, as well as designsin terms of partial engineering forcertain plant ranges. All customerrequirements, including space, pro-duction capacity, refractory quality,steel profiles, fuel type and controlsystem are considered.

Horn offers a complete engineer-ing package for the glass industry,comprising consulting, engineer-ing, design and technical furnacecalculations.

Engineering and Design- general layout plans with differ-

ent colours for each refractoryquality;

- general plans for steel structureassembly with the possibility of3D renderings;

- assembly drawings for refracto-ries;

- assembly drawings for steel;- work shop drawings for steel

with parts lists as well as detailedwelding and material specifica-tions;

- detailed engineering drawings forrefractories with part lists;

- detail drawings of special shapedstones;

- data sheets and complete specifi-cation for each refractory;

- complete documentations ofglass melting plants supplied;

- preparation of documents forplant parts, suitable for tenders;

- statements of final building state;- update of drawings in the final

building state, "drawn as built".

Calculation and modelling- dimensioning of technical fur-

nace and thermal data;- thermal calculations for each part

of the furnace (regenerator, melt-ing end, working end and fore-hearths);

- documents for verifiable statis-tics comprising foundation loadplan and loads;

- modelling of new furnaces and ofexisting installations.

GLASS MELTING FURNACESHorn is the ideal partner for com-

panies producing container glass,tableware, float glass, solar glass,pharmaceutical glass, crystal glass,lead crystal glass, and special glassand supply the furnace concept tosuit the customer’s requirements.

Furnace types- end fired furnace;- cross fired furnace;- recuperative furnace;- full electric furnace;- electric furnace with hot top;- float glass furnace.

FOREHEARTHSHorn GCS Series 200

The Horn GCS Series 200 fore-hearth design is an up to date con-struction employing all the latesttechnology such as modular assem-bly, to achieve optimum thermalhomogeneity combined with mini-mum energy requirement. The steelparts for the forehearth follow cus-tomary design, the foundation isinserted into the steel casing andsteel props brace the superstructure.The superstructure cover blocksused in the cooling zones are spe-cially shaped to realize the best pos-sible heating of the glass. For theforehearth superstructure, silimanitematerial is used and the entire

Horn celebrated the 125-year anniversary of

the Horn enterprise history in 2009, as well as

the 10-year anniversary of the establishing of

Horn Glass Industries AG, with clients and

business partners during a special

celebration and an open day. Horn Glass

Industries AG has extensive experience in the

design, manufacture and supply of different

furnace types for diverse glass types.


Fig. 1 - End-fired furnace



superstructure is backed up withsuitably grated insulation material.The temperature is measured eitherthrough platinum covered thermo-couples or pyrometers.

The forehearth features one ormore radiation cooling openings inthe superstructure cover blocks ofthe cooling zone. These openings aresized and located according to thecooling requirement. Moving thedamper block, which is used to openor close the opening, can vary theactual heat loss through the opening.An electric impulse or an automaticor manual crank regulates the chillopening. The control receives thecommand variable from the tempera-ture control loop of the heating zonein which the radiation-cooling open-ing is located.

The GCS Series 200 forehearthsare used for low to medium tonnagecontainer glass; tableware; glassblocks; cosmetic glass; fibreglass;and special glass (e.g. opal).

Horn GCS Series 300 with forced cooling

In addition to the GCS Series200 features, the Series 300 isequipped with a forced cooling sys-tem in the superstructure and bot-tom of the forehearth. There are sev-eral openings in the centre of theroof block along approximately 75per cent of the length of each cool-ing zone. These openings are cov-ered with a thin refractory tile lyingon the top of the roof block. Thecooling air is generated by a blowerand is led by a canal around thecover and flows out along the cen-tre line. The cooling air leaves thecooling channel on via an openingon the opposite site of the coolingzone. The airflow is steered througha blower with flap Inverter or con-trol flap and receives the signalfrom the temperature regulator loopin the heating zone.

One radiation-cooling opening isforeseen in the forehearth in thesuperstructure cover blocks in eachcooling zone. This opening is sizedand located according to the cooling

requirement. This opening is used inthe case of low forehearth through-put were no centre cooling isrequired. The movement of thedamper block, which is used to openor close the opening, varies the actu-al heat loss through the opening.

The waste gas leaves the fore-hearth via openings located in the centre of the zone laterally onboth sides.

An additional bottom cooling isprovided at the first cooling section.Here a blower supplies cooling air,which is blown in to the canalbelow the channel. The amount isregulated manually.

The GCS Series 300 system isused for medium to high loadedforehearths for production of con-tainer glass; tableware; glassblocks; cosmetic glass; cast/rolledglass; tableware; fibreglass; specialglass.

All-electric forehearthsElectrical forehearths with direct heating

Direct electrical heating refers tothe use of electricity and immersedelectrodes in forehearth channels.The glass bath is used as a resis-tance and the energy is developeddirectly in the glass bath.

The nominal specific currentloading of the electrodes is verylow, so that there is almost no wearof the electrodes. Therefore it is notnecessary to push the electrodes dur-ing operation and no cooling of theelectrode is required.

The most common electrodematerial is molybdenum. Moly-bdenum electrodes are suitable forcoloured soda lime glasses, and forsoft borosilicate C glass. Theseelectrodes are installed horizontallythrough the channel sidewalls. Tinoxide electrodes are used for someapplications, especially for glasscontaining lead.

Installations for containers andsimilar applications have shortelectrodes located at short intervalsalong the complete length of thechannel, with the electrical current

passing across the channel.Channels for fiberglass manufactureuse a smaller number of longerelectrodes installed at larger inter-vals, with the current flowing alongthe channel.

This technology is used for allelectric forehearths in the produc-tion of: soda lime containers, incoloured glasses; fluoride opal con-tainers; C glass for insulating fiber;Pyrex® borosilicate glass.

Electrical forehearths with indirect heating

This heating system involves theuse of radiant electrical heating ele-ments installed in the channelsuperstructure.

There are two types of elements,which are commonly used. Siliconcarbide elements are generally usedin the form of rods, which can beinstalled horizontally across thechannel, with the electrical connec-tions on both sides. These elementscan be used at temperatures up toabout 1,300°C, and operate forabout 18-24 months.

Molybdenum disilicide elements(more commonly known asKanthal Super) are produced as U-shaped elements, which areinstalled vertically through thesuperstructure roof. This materialcan be used at extremely high tem-peratures in excess of 1,700°C andthe elements have a life of four tofive years.

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HOT-END EQUIPMENT

Fig. 2 - Distributor andforehearth system GCS Series100, 200 and 300



This technology is used particu-larly in high quality productionwhen no suitable gas supply is available.

Electrical forehearth combined with direct and indirect heating

Under certain circumstances it isadvantageous to combine direct andindirect electrical heating systems.

Immersed electrodes are installedto provide direct electrical heatingof the glass bath. Additional energyis supplied by radiant electricalheating elements installed in thesuperstructure. In the case of glass-es containing volatile components,a cover tile can enclose the channelwith radiant heating elementsinstalled above the same cover tile.

The use of indirect electricalheating above the glass surface inaddition to the electrodes in theglass increases the flexibility ofthe installation. If the power sup-plied by the heating elements ismore than the heat losses of theglass bath to the superstructurethen there is a net addition of ener-gy to the glass. However, if thepower applied is lower than theheat losses there is a net energyloss from the glass bath and acooling effect is applied.

The combination of direct andindirect electrical heating is typical-ly used for lead crystal glass andPyrex® type borosilicate glass.

Colouring forehearthsThe colouring feeder method is

appropriate for the production of

coloured glass without re-colouringthe whole melting end.

The main advantages are the pos-sibility of applying two colours atthe same time (white and coloured),and a temporary colouring proce-dure. A colouring forehearth isabout 25 per cent longer than nor-mal forehearths. Horn supplies cus-tom-made colouring forehearthsdepending on the relevant applica-tion and condition. The heating andstirring sections are designedaccording to the colour and quantityto be produced in order to achievethe optimum retention time andthus homogeneous colouring.

Specially selected refractories areused in the sections in contact withglass as well as in the superstruc-ture in order to reduce corrosion byfine colouring particles.

Colouring forehearth technologyis used for tableware, beverage con-tainers, cosmetic containers andarchitectural glass.

COMBUSTION EQUIPMENTComplete gas combustion equip-

ment is designed on most moderncomputer stations with CAD.Special programmes assist theengineers at the design and dimen-sioning of the gas equipment. Onbasis of the extensive experienceHorn uses the most reliable anddurable equipment from specialsuppliers are. Each station is pre-assembled and tested in the Hornworkshop in order to avoid loss oftime and faulty assembly on site.

Heating equipment for natural gasHorn supplies the following

components for combustion:1) gas burners;

2) gas reversing equipment;3) gas control and measuring equip-

ment;4) gas safety equipment;5) gas filter and pressure control

equipment.With regards to burner equipment,

Horn provides specially designedburners called Dualflame MC andDualflame AC - Gas burners.

The Horn Dualflame Gas burneris used for installation as an under-port-burner in crossfired or end firedregenerative furnaces. Its designenables the furnace operator toadjust the flame formation smooth-ly in a wide range – from short andsharp to long and soft.

With the Dualflame burner, boththe velocity of the gas and the typeof streaming (from laminar to tur-bulent) can be controlled. If fuelthroughput remains the same,velocity and mixing impulses canhowever be varied at will.

This is achieved by means of twoseparate nozzles inside the burnerlance. The gas quantity can be con-trolled for each nozzle. Thereforethe velocity is altered at the exit ofthe burner.

By adjusting the position of theinner nozzle toward the outer noz-zles the mixing impulse of bothgas streams can be optimized forthe furnace conditions.

With this technical solution, theoperator is able to smoothly adjustflame formation to suit the condi-tions of the furnace layout and ofthe melting technology, withouthaving to change the nozzles itself!The hot spot of the glass melt canbe stabilized with the optimal flamelength. Furthermore, NOx-creationis minimized by the correct mixingFig. 3 - Burner adjustment



impulse of the two gas streamscoming from the burner nozzles.

The replacement of existingburner systems by the Dualflameburner is possible during full pro-duction without any problems orinterruption of the melting process.

Horn offers both manual con-trolled burner Dualflame MC andautomatic controlled burnerDualflame AC.

Heating equipment for heavy oilHorn supplies the following

components:1) burner equipment;2) oil reversing station;3) oil measuring and control sta-

tion;4) oil pressure control and safety

station;5) oil preheating station;

6) oil pump and overflow station;7) oil filter;8) atomizing air reversing station.

The Multiple Oil Burner MOBType 1 and Type 2 is adjusted with

relevant nozzle-drillings. By choos-ing an adequate size of the nozzlethe soiling of the nozzle will bereduced to a minimum.

The air nozzle cross-section has

to be adjusted according to the oilviscosity of the available atomizerair pressure and the desired flamelengths at site. The consumption ofcompressed air is between 0.2-0.5m3/kg fuel and depends from oilviscosity and desired flame-sharp-ness. The available air pressureshould have about 2.5-3.5 bar.

Alternatively, natural gas can beused as atomising agent instead ofcompressed air.

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Fig. 4 - Gas-Air-Mixture station CORA

Fig. 5 - CORA components1Gas-Air-Mixture pipe2Difference pressure orifice plate3Air control valve with electric actuator4Gas quantity adjustment throttle valve5Gas ratio controller with safety

shut-off valve6Gas non-return valve7Suspended flow meter 8Mixture pressure indicator9Mixture pressure guard

FIgure 4

FIgure 5



Heating equipment for oxy-fuelThe following components are

supplied by Horn:- oxygen stations;

• oxygen flow stations;• oxygen control, measuring

and safety stations;• oxygen pressure control and

filter stations;- gas stations;

• gas pressure control and filterstation;

• gas control, measuring andsafety station ;

• burner equipment (by sub-suppliers).

Heating equipment for distributorand forehearths

The mixture heating system,Cora, meets all the heating systemrequirements for distributors, fore-hearths and burners with air cas-ing, e.g. wide and constant controlrange, low maintenance and opti-mum combustion. Pressure fluctu-ations in the forehearth and mixingsystems that do not work constant-ly lead to poor combustion andthus to inferior glass quality. TheCora system from Horn, leads toincreased stability of productionconditions and thus to increasedquality. This is achieved by a constant gas/air ratio across theentire control range, also in case of pressure changes in the combustion chamber. Anotheradvantage is the system design,since it can be integrated intoalmost any mixture heating sys-tem without any difficulty.

MEASUREMENT ANDCONTROL EQUIPMENT

The technological condition of aglass melting plant’s control sys-tem determines the plant’s finan-cial feasibility as well as the qual-ity of the glass produced. Thereforethe most modern visualisationsoftware is used to support theinspection and control of the melt-ing process. The aim is to displaytechnical parameters in the clearestand most user-friendly way and at

the same time achieve the highestpossible safety level.

Horn offers functional units formiscellaneous requirements, pri-marily:- MCC (Motor Control Cabinet)

and electronic within the lowvoltage range;

- measurement and control tech-nology;

- control and automation technolo-gy;

- process supervision technology.To control and govern the com-

plex technological glass meltingprocess, HORN has developed afour-level operational concept:- process supervision and visual-

ization;- PLC - levels with independent

operating units;- back-up hardware levels;- manual operation level.

GLASS LEVEL CONTROL OPTIBEAM

The constant glass level in themelting end is a very importantcontrol component in the glassmelting process. Glass level varia-tion results in irregular operation ofthe furnace, and due to hydrostaticpressure there is significant influ-ence on the gob weight.

The high measuring accuracy ofOptibeam amounting to ± 0,10millimetres allows together withall common charging machines aprecise control of the glass level.The all integrated system standsalone and can be easily operated viaa touch sensitive display.

With the Horn Optibeam allmaintenance work, as well as adjust-ment of the measuring device, maybe effected from outside during oper-ation without any difficulty.

Measuring procedureIn molten condition, the glass

surface forms a smooth surface witha high reflection rate. This physicalcondition is used for a contact-lessglass level measurement with laserbeam. The laser beam hits the glasssurface in an angle of 10-20°.

Dependant from the glass level thelaser is reflected at different pointsat the glass surface and indicates theCCD-line on the camera installed atthe opposite site.

Total range of the camera sensoris -8.0mm +8.00mm based on a ccdrange 0..5000 pixels => 2500 pixelfor the zero point and 312pixel/mm glass level.

The camera evaluates this rawsignal and convert it to a specifiednorm signal of 4..20mA / 0..10VDC, which is then passed to anevaluation unit.

ELECTRIC MELTINGBOOSTING

The addition of an electric boost-ing system can greatly support theglass melting technique. Besideconcentrated regulation of the glassflow, the melting output isincreased due to the Joule effectwithin the glass.

Depending on the existing situa-tion or the customers’ request theboosting system can be manufac-tured for melting boosting with lat-eral and bottom electrodes, as barri-er boosting or as throat boosting. Acombination of these systems isalso possible.

When designing the boosting sys-tem Horn applies the latest technicalaids as well as its long experience ofboosting system installations.

Melting boosting and barrierboosting mainly increase meltingpull and quality by concentrated reg-ulation of the convectional flow.

The purpose of throat boostingis concentrating heat input in thethroat in order to prevent “freezing”of the glass in this zone, mainlyduring the starting stage with dark-er glass colours.

The boosting systems can beequipped as one-phase or multiple-phase systems. Depending on thesituation continuous thyristor-con-trolled systems or a continuouslyworking transformer may be used.

When designing such systemsHorn take into account both opti-mum operational function and opti-


HORN GLASS INDUSTRIES AG

Bergstrasse 2 - Postfach 62, D-95703 Plössberg - Germany

Tel: +49 - 9636 - 92040 - Fax: +49 - 9636 - 920410E-mail: [email protected]

www.hornglas.de


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mum integration in the existingelectric network.

All boosting systems suppliedby Horn are fully installed and com-missioned.

BATCH CHARGERSHorn provides specially in-

house developed and manufacturedbatch chargers for different furnacetype. The following chargers areavailable:- Vibratory Charging Machine –

HVR;- Piston batch charger (HK);- Screw batch chargers (HS);- Cold top batch charger.

ANNEALING LEHRSRoller Annealing LehrApplication:

Annealing ornament-, wired- andU-profiled glass, width of glass upto 4,000 millimetres and thicknessof the glass 2-16 millimetres.Construction and configuration:- cooling tunnel consisting of the

heating and cooling sections, eachof which is equipped with a forcedair circulation and a temperaturemeasurement and –control;

- free end of lehr;- conveying rollers with group dri-

ves, frequency controlled;- heating with gas burners or heat-

ing registers;- measuring and control equip-

ment.

Options:Scraper conveyor for automatic

shard removal.Features/benefits:- excellent annealing due to the

even air flow above and belowthe glass (optimized via comput-er simulation);

- low energy consumption due tothe high grade insulation;

- highest reliability due to thefully developed technology;

- long lifetime due to the stableconstruction;

- consideration of specific require-ments of the customer.

SPECIAL THERMOPROCESSING MACHINES- mould preheating kiln;- hot end coating unit;- cold end coating unit. ■

FIgure 6

Fig. 6 - Melting and Bottom boosting

Fig. 7 - Glass level control system OPTIBEAM

FIgure 7


Know-How,

experience and

continuous

investments in the

latest glassware

mould

manufacturing

technologies for

over 25 years.

Manufacturing

"top-notch quality"

glass moulds for

automatic press,

press-blow, blow-

blow, stemware

lines, T/T -Twin table

and spinning glass

production

processes, this

company is

continuing its

production using

high-tech CNC

milling, lathe, and

electro-erosion

machines and,

along with its

trained personnel,

to offer the best

service at all times,

concentrated on

client satisfaction.

ehind Merkad’s continuousgrowth and development,there is dedication and concentration on quality

in every step of the pro-duction process. Merkad continu-ously researches and developsmould-manufacturing techniques,using the latest technologies and materials in order to provideits customers with the best avail-able quality.

NEW TECHNOLOGYINVESTMENT

Merkad has Invested on threeunits of the latest machines: "3 Axis- CNC Vertical", "3 Axis CNCHorizontal" and "CNC Lathe"Machining Centers in order to pro-vide more capacity to its tablewareclients who require high qualitymoulds for their glass productions.

Starting right from the designphase, Merkad’s design team collab-

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Merkad:

TOTAL QUALITYASSURANCE from designto production


B

Merkad art GM 1-04-2010 10:47 Pagina 43

orates closely with clients to findthe best solutions, overcome possi-ble difficulties in product design,finding and suggesting innovationsand improvements, all by means ofsoftware simulations.

Merkad’s Engineering & Designdepartment provides professionalservice including moulds andequipment for glass productionsuch as pressing, blowing, stretch-ing, spinning and stemwareprocesses, right up to the design ofarticles with related technical draw-ings, and 3D modelling.

This means that many importantdetails can be calculated and reflect-ed to technical drawings, including:• determining cooling profiles of

plungers and moulds;• identifying dimensions and the

area of exhaust holes in blowmould cavities;

• parison design and calculatingthe allowance of parison hangingin production of stretchingstemware; and

• obtaining homogeneity, glassthickness and ovality on spin-ning moulds.

ENGRAVINGThe process for engraved moulds

begins with a rough draft of thedesign required, which is then con-verted accurately into a 2D technicaldrawing. Dimensions and amountsof engraving on the mould are agreedafter in-depth discussion betweenMerkad and the client.

The next step is to convert the2D image into a 3D relief usingartistic CAD/CAM software. Acomputer simulates different scenar-ios to test the overall design andfeasibility of the mould once it is inuse for production.

Being able to make all the balanc-ing and homogenizing glass volumedistribution adjustments in this envi-ronment also guarantees a greaterlevel of accuracy, which is extremelyimportant for engraved spinningglass production techniques. Afterthe design details have been finalized,Merkad submits the data, suppliedby DXF, STL or IGS data transla-tors, to clients for approval. Thesetest give Merkad and its customer theopportunity to address any designelements that might be incorrect orcause problems such as the glassproduct splitting when it leaves themould. The procedure is primarilycomputer-based and, therefore, soany modifications can be madequickly and easily.

The final step is to produce themoulds carefully using the CNChigh speed machining.

Another method, which Merkadutilizes successfully for relief creat-ing, is Reverse Engineering. Withthis particular method, a samplerelief model is scanned and thencopied in 3D. After making all nec-essary and requested changes on themodel, Merkad carries out the pre-cise wrapping of the relief on a newbase surface.

When the design is completed, itis possible to enter Merkad’s websiteand, from the “Members Link”,reach the area where the moulddesign or model can be seen andevaluated. A special “User ID” and“Password” is provided by Merkadfor this service.

Merkad has also created a new,user-friendly “upload” section whereits clients can send their heavy files.

PRODUCTION AND PLANNING

Merkad’s production departmentis fully equipped with "state-of-the-art" CNC High-Speed MachiningCentres, CNC Lathe and ElectroErosion machines, and the mostsophisticated CAD/CAM systemfor flexibility in manufacturinghigh-quality mould equipment.

Merkad’s process expertise startswith highly trained personnel, uti-lizing a CAD/CAM system, whichis capable of interacting over theworldwide web with individualcustomers.

Special process in the productionrange of Merkad includes:• Stellite and colmonoy welding

with hardness 32-45 HRc (for plunger, bottom plate, neckring jaw);

• Ceramic coating with hardness58-60 HRc (for mould holderrods etc.);

• Electroerosion processes withCNC EDM (Electrical DischargeMachines) by utilizing graphiteor copper electrodes (for blanks,blow moulds etc.);

• Hard chromium coating withhardness 56-58 HRc (for blanks etc.).

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Blow Mould Holder and Blow Mould



HVOF (HIGH

VELOCITY OXYGEN FUEL)THERMAL SPRAY PROCESS

With this sytem Merkad provideshigh quality and long life plungersto its clients. Plungers coated usingthe HVOF system ensure three tofour times more lifespan in glassproduction compared to other stain-less steel plungers known for glasstableware production. This is a veryimportant saving point for glass-makers to reduce their plunger costsseriously.

Merkad’s production planningteam also uses ERPsoftware, inorder to track all jobs along the waythrough the production process, thusenabling the company to give thebest accurate production and deliverytime to its customers. Other types ofspecialized processes include powderwelding, ceramic coating and hardchromium coatings.

QUALITY ASSURANCEMerkad has ISO 9001:2000

Quality Assurance SystemCertification and concentrates great-ly on maintaining the quality of itsproducts at international level.

Production is controlled by tak-ing sub-measurements after eachoperation, and after passing 100per cent quality control, each pro-duct is supplied with final controlreports and certificates of analysesof materials controlled by Merkad’sQ.A. department and internationalaccredited laboratories.

Merkad also has a calibration labwhere it calibrates its measuringdevices with gauge blocks andtesters, which are traceable accordingto an international system. Havingan internal calibration lab providesshorter calibration periods.

MOULDSPress process moulds

Merkad manufactures complexmoulds requiring extensive engineer-ing and precision machining, such aspress mould equipment for pressmachines, including; moulds, blank

holders and inserts, plungers, plungerrings, bottom plates, and so on.

The company uses hot worktool steel and stainless steel mate-rials with the ESR process, espe-cially developed for glass mouldproduction, and manufacturedusing the double forging process at30-32 HRc hardness.

Since this type of material doesnot need any extra hardening orchromium coating, Merkad’s cus-tomers have the advantage ofworking with mould equipmentthat has a longer lifespan than itscompetitors and without the needof any extra processing duringglass production.

Moulds for blow processWith regards to blow mould

equipment, Merkad supplies: block

moulds, inserts, plungers, guiderings, neck rings (four-part), blowmoulds, bottom plates, vacuumheads, graphite holders, etc., whereparison designing knowledge gainsgreat importance. Thanks to a spe-cial software program, Merkadengineers simulate the movementof the parison under different pro-duction circumstances, thus fore-seeing any kind of problem whichmay occur during the blow glassproduction.

Merkad also provides the follow-ing information when a completeblow mould set is provided:1. calculation of the parison which

they need to work with;2. allowance of parison hanging,

after pressing process; and3. weight of the final glass item,

after crack-off or burn-off.

Moulds for stemware linesMerkad’s stem mould equipment,

which uses 1.2782 stainless steelwith double forging and ESRprocesses, includes: stem moulds,plunger rings, plungers, bottomplates, working table rings (three-part working tables). The moulds,which reduce the traces on the sur-face of glassware caused by mouldsplit lines, even in very complexstem figures, and especially withirregular joint contours.

The moulds are prepared in twoor three pieces, depending on theshape of the glassware.

Moulds for spinning processSpinning moulds manufactured

by Merkad, using 1.2787 stainlesssteel with ESR and double forging,can be used at the maximum rotation

45glass machinery plants & accessories 2/2010


Stem Moulds from Merkad

Blow Mould

Holder

MERKAD MAKINA LTD.

Gumussuyu Cad. Karacabey SokakEnder Kitapci Is Merkezi 1034020 Davutpasa - Istanbul - TurkeyTel: +90 - 212 - 4830710Fax: +90 - 212 - 4830727E-mail: [email protected]

www.merkad.com

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capacity of machines, with the helpof cooling profiles designed byMerkad’s Engineering Department.

Regardless of how hard and howcomplicated glass designs are, allpossible problems that could effectdecorations are eliminated duringdesign. After final confirmation,the decorations are applied to themoulds.

Moulds for borosilicatepress process

Merkad uses1.2787 stainlesssteel material with 34-37 Hrc hard-ness for its borosilicate mouldsand equipment, which includes:

moulds, rings, ring holders,plungers, plunger cooler boxes,plunger holders.

For plungers, special powderweldings are utilized to give extrahardness on plunger surfaces with 45 Hrc, along with specialcooling profiles to ensure long-lasting plungers and high qualityglass products.

SPARE PARTSMerkad’s specialized spare parts

are manufactured according toclients’ requests:

• high precision neck ring holdersfor press & blow machines.Ovality, perpendicularity and par-allelism tolerances of neck ringsmaximum ±0.015 millimetresduring closure.

• high-tech mould holders for press& blow machines, to eliminatetraces and split (parting) lines onglassware;

• mould holders for press machines; • mould holders for stemware

machines; • neck rings (3-4 part); • working tables; and • working table holders. ■



NTRODUCTIONMan has been making use of

glass from the very beginning ofhis existence. Historians have

discovered that a form of naturalglass - obsidian - formed within themouth of a volcano as a result ofthe intense heat of an eruption

gla

ss co

nta

ine

rsGLASS CONTAINERS

Vidromecanica:

THERMAL-SHOCKMACHINEStesting the resistance of hollowglass to thermal changes

47

I

Few of us can imagine modern life without glass.

It is in almost every aspect of our lives - in our

homes, our cars and whenever we sit down to eat

or drink. Glass packaging is used for many

products: water, wines, spirits and beers all come

in glass as do medicines and cosmetics, not to

mention numerous food packages.

In this article Vidromecanica discusses the

equipment used in the container glass industry for

quality control of articles from the production

process (after annealing thermal treatment).


Vidromecanica art 26-03-2010 12:57 Pagina 47

melting sand - was first used byman as spearheads.

Today, glassmaking is a modern,hi-tech industry operating in afiercely competitive global marketwhere quality, design and servicelevels are critical to maintain mar-ket share.

Vidromecanica, a leading compa-ny in the glass industry, manufac-tures thermal equipment (forannealing, decorating and temper-ing); equipment for coating treat-ment (hot-end and cold-end coating)and cullet processing plants.

The development, design andmanufacture of machinery, develop-ment of the control system, controlpanel construction and softwareprovision for the production linesare managed by our own in-housespecialists.

Our technology results from ourmain technicians experience ofdecades and from our tight coopera-tion with many glass factories.

MODERN GLASSMAKINGModern glass plants are able to

make millions of glass containers aday in many different colours.

When glass is made, it is heatedto around 1,600°C, thus killing off

any bacteria, while organic chemi-cals that might be present in therecycled glass are burned. This iswhy glass is used to pack productsof premium quality – because nocontamination from packagingoccurs. Glass is elegant, and glass

packaged products stand out. Withmany unique shapes, glass con-tainers give your product identityand character. Glass is fully recy-clable - a glass bottle can beremade into a new, clean glass bot-tle. This is why glass is a trulyenvironmentally friendly material– now and in the future.

DESCRIPTIONThe thermal-shock machine is

used to test the resistance of hollowglass to thermal changes (Δ T <100°C) due to:- hot packing processes;- article transfer from hot to cold

surrounding or vice-versa;- washing operation;- pasteurization.

The machine manufactured byVidromecanica is essentially made upof a basket where the containers areplaced in vertical position, and by

two tanks, one containing hot waterand one containing cold water.


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GLASS CONTAINERS

Lateral view of Thermal ShockMachine

ASTM C149This test method covers the determination of the relative thermal shock resistanceof commercial bottles and jars and is intended to apply to all types of glass contai-ners that are required to withstand sudden changes in temperature in service. Thetest apparatus consists essentially of a basket for holding the glassware upright, ahot water tank, a cold water tank, and a timed means for immersing and transfer-ring the basket from the hot to the cold bath. Indicating controllers or dial thermo-meters should be used to maintain the temperatures of the baths. Test proceduresincluded in this specification include pass tests, progressive tests to a predetermi-ned percent of breakage, total progressive tests, and high-level tests.

ASTM C224This practice covers the standard for sampling of glass bottles, jars, and other con-tainers intended for use in testing mechanical strength, dimensions, and othermeasurable characteristics.Sampling from a continuous manufacturing process shall be in accordance with a

time schedule. When testing for annealing affected characteristics, samples shallbe taken from the exit of the lehr (or from packed cases whose continuity in pointof time is known). For characteristics not affected by the degree of annealing,quickly cooled samples may be taken ahead of the lehr. Samples may come fromthe lot as a whole or it may be necessary to sort the lot before sampling. Sortingmay be based on style, colour, size, manufacturer, or mould designation.Containers packed in cases shall be removed from the lot at random.

NORMS


VIDROMECANICA

Rua Central 22, Garcia2430 Marinha Grande - Portugal

Tel: +351 – 244 – 555060Fax: + 351 – 244 – 552410

Email: [email protected]

www.vidromecanica.com

Both tanks have water circula-tion to assure uniform temperaturein every point of the bath. Themachine has two pumps to main-tain water at the required tempera-ture by circulation of hot water andcold water. Both tanks have a ther-mometer granting accurate readingof the water temperature. The pro-gramme on the PLC transfers thecontainer basket from the hot- tothe cold bath.

NORMSOur machine respects ASTM-C

149 testing regulations and it isable to execute ASTM-C 224 test-ing procedures.

FEATURES OF THE MACHINEFunction: test the thermal

shock resistance of hollow glasscontainers.

Duration: the test lasts about sixminutes (automatic or manual cycle).

The equipment madeby Vidromecanica is pro-vided with one hot- andcold water temperaturecontrol system consist-

ing in two temperatureregulators and two thermocou-

ples. One regulator controls thewater temperature inside the coldtank through the control of one coldwater supply solenoid valve connect-ed with water inlet. The temperatureregulator controls the closing of thecold water supply solenoid valvewhen the programmed temperature isobtained. The second regulator con-trols the water temperature inside thehot tank through one closed circuitwith an external electric heatingresistance. The cold- and hot tankshave one circuit with pumps for con-tinuous water circulation from thelower- to the upper part. Consideringthe 20°C inlet water and having thepossibility to heat the water up toabout 90°C, the maximum thermaldifference is 70°C. The time formaintaining the containers inside thetanks is regulated by two indepen-dent timers. The system quicklytransfers the basket from the hotbath to the cold bath.

Our equipment also has waterlevel probes on both tanks, whichcheck the minimum level needed ineach tank to enable the system tostart operation. Checking takes placewhen the control panel is switchedon and when the basket is stoppedbefore water heating or automaticcycle start. If the water level in thehot/cold water tank is below mini-mum, the pump and the water heat-ing resistance are not activated butthe solenoid valve which supplieswater to the hot- or cold water tankwill open until the minimum safetylevel is obtained. Permission to heatthe water and run the pump for coldwater is only given once this mini-mum level is attained.

The tanks have a useful capacityof 300 litres and their dimensionsare 750 x 750 x 600 millimetres.The machine is manufactured inhigh quality stainless steel, andeach basket can contain up to 15bottles per cycle.

The thermal shock test equip-ment has a protection system tostop it from working if the workingarea of the basket is violated.

The machine is supplied with acontrol panel in accordance to CEnorms ready for connection to theelectricity and water supplies.

The thermal-shock machine,produced within the EuropeanCommunity, has CE mark and rel-ative Declaration of Conformityregarding the general Europeansafety norms and the harmonizednorms compiled by the EuropeanCommittee for Machine Safety.

QUALITY MANAGEMENTIn the late 1990s, Vidromecanica

established a Quality ManagementSystem to control its order fulfil-ment process: specifying, design-ing, building, testing, shipping,installing, and commissioning.Suppliers were included in the qua-lity management through detailedtechnical specifications, goodsinwards inspections, and supplierassessments.

Every year an independent auditorentity certifies our QualityManagement System according toISO 9001. ■


Electrical panel of Thermal ShockMachine

THERMAL SHOCK MACHINETechnical featuresElectric feeding: 220/380V - 50Hz

Total installed power: 32 kW

PLC to control the equipment

Water feeding:

Pressure: 1.5 to 2 bar

Consumption: 0.15 to 1 m3/hour

Weight: 1000 kilos

Overall dimensions:

Length: 2500 millimetres

Width: 1500 millimetres

Height: 2000 millimetres



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MELTING TECHNOLOGY

Alfeo Caputo - Chief TechnologistMarco Ferrari - Tech. Dept - General Facilities

GLASS TECHNOLOGIES

n recent years we have been see-ing continuous improvement inmelting technology, thanks tothe availability of better per-

forming refractory materials and tothe implementation of tools andtechniques, which have led to sig-nificant results in terms of energyefficiency, emission reduction, andlonger furnace life. One of the areasthat has gained less benefit from thenew opportunities offered by thesenew technologies, however, is thecharging of raw materials into themelting furnace.

I

Glass Technologies:

A NEW APPROACH TOBATCH CHARGING

While the performance of refractory ma-terials, along with tools and techniques,have been improved and implemented,one of the areas of glass melting that has notseen any kind of benefit is that of chargingmaterials into the furnace.In this article, Glass Technologies shows ushow this area can been bettered with aneffective distribution of raw material onto themolten glass surface inside the tank thanks toits sealed dog-house charging machine.

Considering the importance ofoptimizing all process phases toachieve the best results is so wellknown that it is surprising that theraw materials charging techniqueshave always been considered so lit-tle promising from this point ofview, and have often remainedunchanged for decades.

It is worth remembering that thefunction of the charging machine isnot only the feeding of the rawmaterials into the tank but alsospreading them onto the glass sur-face in the shape of islands, whichshould expose a wide surface to theflame radiation and at the same timeremain detached from each other,thus enabling the heat to penetratedeeply into the molten glassthrough the empty space betweenadjacent islands.

It is equally important to avoidthat raw materials reach the meltingtank walls when entering the fur-nace as this contact could cause pre-mature corrosion of the refractorymaterial, thus shortening its life.

Last but not least, it is veryimportant that the charging machinekeeps the inside of the furnace wellinsulated from the outside so that noparasite air can leak into and noflames or hot gas can go out.

Even though all of the above iswell known, it is easy to verify thatmany of the existing furnaces nowin operation and designed accordingto modern concepts adopt raw mate-rials charging systems of an opentype, i.e. systems which do not pre-vent the air leakage into the furnace.The consequences are a negativeimpact on energy consumptions,Nox emissions, along with easierexhaust of dust, all of which lead touncomfortable and unhealthy condi-tions around the charging area.

Moreover, most of the time, suchsystems are of a fixed or semi-fixedtype. A fixed system cannot push thematerials charged in more than onedirection and therefore it cannot dis-tribute them onto a large area of themelting surface. A semi-fixed sys-tem enables a modest rotation of the

turret around the verti-cal axis with a limitedangle, normally inferiorto 20°, which cannotpermit an effective dis-tribution of the rawmaterials onto themolten glass.

There are other fur-naces which areequipped with closedcharging systems, hav-ing an oscillating turretwith wide rotationangles, up to almost45°. Such systems haveundoubtedly manyadvantages if comparedwith open dog-house systems, eitherfixed or semi-fixed, but the controltechnology of such systems hasalways been limited to an increase ofthe turret positions from 3 to 5,never approaching pusher kinemat-ics control and therefore reducing dra-matically the possibility of chang-ing the shape and distribution of thebatch islands on the molten glasssurface inside the tank.

It should be mentioned, however,that the adjustment of the chargingdynamics parameters requires somemechanical regulations to be carriedout on the machine itself after it hasbeen stopped. This procedure affectsmelting process stability and forcesoperators to work in a hot and dustyenvironment.

It is therefore easy to understandthat the adjusting operations,whose efficiency is already reducedbecause of the technological limitsof the kinematics mechanics, aregreatly discouraged by the need ofworking in a difficult environment.

Well aware of all above describedproblems and wishing to give fur-nace operators the best instrumentsto optimize the charging processwithout any of the above limita-tions and hindrances, GlassTechnologies (GT) has developed aninnovative control process of thecharging phase for sealed dog-housemachines, enabling the control ofthe entire charging process via oper-

ator panel, with the machine inoperation and without the need formechanical intervention on themachine itself.

THE ELECTRONICOSCILLATING BATCHCHARGER (PATENT PENDING)

The electronic batch chargerconceived by GT is a sealed dog-house charging machine: it canmaintain the inside of the furnaceclosely separated from the outsideand make the turret turn with arotation angle up to 45°, so thatthe raw materials are effectivelydistributed onto the molten glasssurface inside the tank. Such capa-bilities have been known andappreciated for some time now.GT’s innovation consists of a newcontrol method of the mechanicalmovements, which free the pusheraction from the intrinsic limits ofthe mechanical kinematic motion.

Pusher actionThe sealed doghouse charging

machines are equipped with a push-er, which literally pushes the rawmaterials into the furnace with aforward/backward movement con-trolled by a crankshaft-rod mecha-nism. This mechanism is, in turn,controlled by a ceaselessly rotating


Figs. 2 and 3 - Oscillatingbatch charger

Figure 2

Figure 3


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MELTING TECHNOLOGY

driving motor. While the pusher isin a backward position, the rawmaterials drop onto the moltenglass surface and are pushed into thefurnace by the same pusher duringits forward movement. The piston-handle kinematics determines themoving speed, which varies accord-ing to a sinusoidal law in which theminimum speed corresponds to thestroke extremities, i.e. to the maxi-mum extraction and maximuminsertion points of the pusher.

From the point of view of thebatch islands and the possibility toshape them, the above-describedsystem suffers some significantlimitations and offers few possibil-ities of intervention. During thepushing forward phase, the pusherreaches its maximum speed athalfway of the stroke, diminishingit in the second half until it stopsand then starts the backward stroke.The raw materials, pushed by thepusher, lean onto those loaded withthe previous stroke and it is notpossible to create a divisionbetween two subsequent loads.

As a result, as is often observed,the batch creates a series of cords orone wide blanket, composed of var-ious subsequent loads resting orleaning on each other and floatingon the molten glass surface forquite a long time.

The pusher stroke adjustment cansometimes lead to some improve-ments but to do so it is necessary tostop the machine and carry outinconvenient on board regulation.

ADVANCED PUSHER CONTROLThe principle of GT’s innovation

is based on pusher movement con-trol, now free from the constraintsof kinematic mechanic motion.This is possible thanks to the servomotor used to drive the pusher andthe partial rotation of the crank-shaft-rod mechanism within a max-imum angle corresponding to thepusher maximum stroke, as shownin the picture below.

The characteristics of the servo-motor enable to manage pushermovement speed according to aseries of parameters which can bekey-entered by the operator withoutthe need of mechanical adjustmentson the machine.

It is therefore possible to dividepusher backward and forwardstrokes in various segments so asto define the acceleration and decel-eration laws for each of them andto determine stop positions:• P4 maximum possible pusher

stroke serviceable angle,adjustable by the operator. Thesum of P4 and P6 corresponds tothe total 180° rotation of thecrankshaft-rod axis;

• P5 maximum serviceable anglepusher movement correspondingto the loading method (see later);

• P6 pusher final stroke anglecorresponding to the maximumspeed necessary for the final push.The result is that the push-

ing impulse given to the raw ma-terials to load them into the furnacehas two main effects. First of all,

due to the pressure exerted the loadtends to form a high and narrowpile; and, secondly, thanks to theacceleration imparted, the materialsare pushed deeply into the furnaceso that two sub-sequent loads donot pile onto each other and somedistance remains between them.

The pusher cycle can be betterdescribed if divided into phases:• Pushing Phase

- the pusher get started and accel-erated up to maximum speed;

- the pusher continues itsstroke at the maximum speeduntil it reaches the forwardstroke limit;

- having reached the strokelimit, the pusher stops for apre-set period of time;

• Returning Phase- once the stopping time is fin-

ished, the pusher returns to itsoriginal position at a pre-setspeed until it reaches the back-ward stroke limit;

- having reached the strokelimit, the pusher stops for apre-set period of time.

All above described parameters,represented with letter “P” on the control panel, can be set by the operator thanks to the menushown in video (Figure 8).

TURRET ROTATION CONTROLThe turret rotation angle can

reach 45° depending on the dog-house design.

Rotation control is based on theon a rod-handle mechanism prevent-

Fig. 5 - Conventionalcharging machine loading pattern

Fig. 4 - Management of pusher speed by means of servomotor

GT GLASSTECHNOLOGIES SRL

Via J. Massarenti 929100 Piacenza (PC) - ItalyTel: +39 – 0523 – 623058Fax: +39 – 0523 – 609785


www.glasstechnologies.it

ing the turret from exceeding themaximum angle designed. Thissolution is intrinsically safe: itmakes it impossible to exceed themaximum rotation angle and use-less to install the limit switcheswhich are usually installed on othermachines present on the market.

Thanks to a digital encoder, it ispossible to set all intermediate halt-ing positions of the machine directlyfrom the control panel and within themaximum rotation angle. The basicprogramme includes a maximum offive but it is also possible to increasethis number upon request.

The control software makes itpossible to set:• the angle of each arresting posi-

tion of the turret;• the positioning sequence of the

turret, from one position to thefollowing one;

• the stopping time for each posi-tion or, as an alternative, thenumber of the pusher strokes.It is also possible to save a dif-

ferent menu of the pusher move-ment for each position of the turret,with different parameters for eachdifferent position.

RAW MATERIALS LOADING METHODS

In order to keep the glass levelconstant inside the furnace tank, thebatch charging machine has to beable to vary the quantity of the rawmaterials to charge according to theoutput signal coming from the glasslevel measuring and control signal.

Depending on the type of batchcharging machine, this signal acts either on the vibration

intensity of the vibrating feeder(open dog-house) or on the pushermotor number of rounds (sealeddog-house).

GT’s electronic batch chargeroffers two different methods of rawmaterials loading which can beselected from the operator panel:• Frequency Mode

- the quantity of the raw materi-als charged into the furnace isadjusted by controlling thenumber of machine-cycles intime according to the glasslevel regulating signal, simi-lar to the regulation of thepusher motor number ofrounds used on conventionalmachines.

• Stroke Span Mode- the quantity of machine cycles

remains constant and the glasslevel control signal acts onthe pusher stroke;

- the pusher action can be com-pared to a slide valve and itsopening is controlled by theglass-level measuring system;

- this mode enables to controlthe pusher stroke keeping it aslimited as necessary for theraw materials to drop onto themolten glass surface.

The possibility to choosebetween the two modes combinedwith the possibility of controllingthe pusher stroke as describedabove offers an unparalleled levelof flexibility in the charging ofraw materials with many possibleadvantages:• high constancy of the glass

level;• lower emissions of dust in the

dog-house area;• cut down of air leakage through

the dog-house;• wide range of possible interven-

tions on the batch island shapeand distribution on the moltenglass;

• easy adjustment to different batchhumidity and smoothness condi-tions;

• increased effectiveness in pre-venting the melting tank refrac-tory structure. ■

Fig. 6 - Electronicbatch charging load-ing pattern

Fig. 8 - Parameters shown in video


he ICG (International Com-mission on Glass) is a non-profit international society ofnational scientific and techni-

cal organizations with particularinterests in glass science and tech-nology. It was founded in 1933 andhas grown to become the recog-nized worldwide organization inthe field of glass with presently 33member organizations bringingtogether the world's most respecteduniversities, scientific institu-tions, companies of the glassindustry and allied organizations.

The aim of ICG is to promote andstimulate understanding and coopera-tion between glass experts in thefields of science and technology aswell as art, history and education.

MEETINGS

ICG is a non-profit international glass

society consisting of 33 national organi-

zations in the glass science and

technology sector. The aim of ICG is to

promote cooperation between glass

experts. ICG organizes workshops

(laboratory round robins, publication of

scientific and technical papers). ICG also

organizes, every three years, the

International Congress on Glass.


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International Commission on Glass

PREPARES FOR THENEW DECADE

ICG art 1-04-2010 11:01 Pagina 54

The ICG achieves these objec-tives by organizing TechnicalCommittee work (e.g. laboratoryround robins, comparative studies,topical meetings), compiling infor-mation on glass (e.g. publishingscientific and technical papers,reports and books) and by sharingand disseminating knowledge onglass in advanced educational cours-es and workshops.

A further major role is to orga-nize international meetings: everythree years the ICG holds anInternational Congress on Glass.Annual Conferences take placeduring the intervening period oftenin conjunction with national soci-ety meetings.

The ICG is financed by subscrip-

tions from Member Organizationsset in proportion to the annual glassoutput of the respective countries.Additional income arises from thesale of publications and royalties.

ICG also gains considerablyfrom contributions 'in kind' fromindividual members of the adminis-trative team and technical commit-tees who give freely of their timeand effort.

FUTUREThe International Commission

on Glass has had a very successfulperiod of more than seven decadesduring which it has welcom-ed many new member organiza-tions. Many well-known glass sci-entists and technologists are

involved in its organization and itis run by a committed and experi-enced administration.

Participating organizations inthe ICG enjoy hands on experienceand achievement through involve-ment in TC activities.

Major benefits are gained fromdirect association between interna-tional glass experts in the fields ofscience and technology, art andeducation and through liaisonswith related fields of technologysuch as optics, photonics, elec-tronics, nanotechnology, coatingtechnology, biotechnology, poly-mers and composites.

The ICG is determined to contin-ue its high standards of quality andperformance.


ABOUT ICG

ICG art 1-04-2010 11:01 Pagina 55


For the future, its aim is toencourage:- More national institutions to

join as members;- More individuals to serve on

ICG committees;- Proposals for the establishment

of new technical committeescovering pertinent topics.

NEW PRESIDENTAt its annual conference held in

Vancouver in June of 2009, theInternational Commission on Glassadopted a number of important freshinitiatives under its new President,Fabiano Nicoletti. Key objectivesfor the future include greater global-ization of activities and opening upthe organization to more majorglass companies.

Recent years have seen: the effec-tive re-organization of TechnicalCommittee activities and theCoordinating Technical Committeeby Klaus Bange; the successful con-clusion of the important Europeanproject EFONGA by René Vacher;the creation of important RoadMaps for future glass technologydevelopment, by Ruud Beerkensand Wolfram Hoeland in particular;and a new modern ICGConstitution that opens up theorganization to individuals and tointernational glass companies.

A number of important stepsstill need to be taken. First of all, itis agreed that all future ICG activi-ties must be global. And to achievethis goal, greater involvement ofthe BRIC countries: China, Brazil,Russia and India is perceived to bevital. The first three of these havealready pledged to contribute to thesuccess of this new age and willthus be assuming greater responsi-bility, and taking on more duties,within the framework of the ICG.The President Fabiano Nicolettiindicated that India will most likelyfollow suit. He noted that Europe,the United States, Japan, China,Russia, Brazil and India need tointeract in order to identify commonobjectives for the promotion of

glass and the advancement of glassscience and technology.

Greater involvement of the higherechelons of glass companies is alsobeing encouraged by allowing themto participate directly in ICG deci-sions as a way of achieving continu-ous and effective interaction.

Furthermore, the effectivenessof the National ParticipatingOrganizations (NPOs) in represent-ing their constituencies still needsto be verified. Their know-ledge ofand interaction with the nationalindustrial glass community meritsimprovement. The NPOs shouldcontribute toward the initiatives ofthe ICG and support them in anoperational manner, for instanceby providing training teams,encouraging national glass produc-tion, identifying new and/or localfinancing sources and proposingnew activities. Fabiano Nicolettiunderlined that they should be thefirst vehicle for providing and dis-seminating information in theirrespective countries.

He requested that the SteeringCommittee Members become moreactive in all areas; for example ateleconference for the SteeringCommittee would be organizedevery two months.

It was also agreed that theresearch activities of the ICG’sTechnical Committees need to bemore oriented towards a modernSustainable Low-Carbon Society(SLCS), in which high-tech glasseswill be required to support energysaving and environmental protec-

tion initiatives. One key to thegrowth of glass applications will bea better understanding of glass sur-faces and the development of moreand more products that utilize thin-film technology. Furthermore,function-oriented glasses in combi-nation with non-glass products needto be considered and examined. AsFabiano Nicoletti put it, “Weshould focus our attention on theareas with increasing demand, forinstance glass fibers, heat-resistantglass, glass for electronic devices,medical, biotech, generating energysavings and storage, and on the fun-damental research necessary to pre-pare the next generation of glassproducts.”

He also made it clear that, accord-ing to the constitution of the ICG,the art and history of glass shouldreceive appropriate attention. Aneffort will now be made to verify andidentify the existing internationalbodies in these fields that might beassociated with the ICG.

THE COORDINATINGTECHNICAL COMMITTEEAND STEERING COMMITTEEMEET IN VENICE

The Coordinating TechnicalCommittee (CTC) and SteeringCommittee of the InternationalCommission on Glass (ICG) met

Inte

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wMEETINGS

FabianoNicoletti

ICGPresident

TC MEMBERS SOURCES

ICG art 1-04-2010 11:01 Pagina 56


on Thursday 29 October, for thethird time in 2009. The venue wasthe Sala Barbantini, often used forinternational events and situated onthe small Isola di San GiorgioMaggiore in Venice, Italy.

This CTC meeting was the firstsince René Vacher took over asChairman from Klaus Bange andhe immediately focused on devel-oping the ideas that arose out of the analysis of cluster activ-ities at the previous CTC meet-ing in Vancouver (June 2009). Inparticular he proposed to use thisopportunity:1) as a platform for initiating dis-

cussions on managing the outputof the Technical Committees(TCs);

2) to identify gaps in coverage with-in the overall cluster activities;

3) to uncover the potential for newsynergies.

Basic Science ClusterWithin the Basic Science Cluster

for which he is responsible, René

Vacher highlighted the need forstudies on ‘Structure and vibra-tions’ and ‘Atomistic simulation’to complement and supplement theoutput of TC03 on Basic Science,which has an emphasis on diffrac-tion studies. Two new committees(TC26 and TC27) have been commissioned to develop theseareas. New committees onNanomechanics (TC09) and theGlass Transition (TC08) are devel-oping their work programmes andtheir linkages to other committees(e.g. TC09 with TC19), and TC08has opportunities to move intoareas such as relaxation in highlyviscous liquids. TC07 (Nucleation,crystallization and glass-ceramics)with TC10 (Optical properties ofglass) both work at the boundarybetween fundamental science andapplications, to their advantage butalso needing careful control.Similarly René Vacher questionedwhether TC02 (Chemical durabili-ty), although working very well,might benefit from input from

other committees such asTC19; he sees such syner-gies as a key factor to unlocknew output.

Glass Production ClusterThe Glass Production Cluster,

under the leadership of RuudBeerkens, has a particular reputa-tion for hard work and effectiveoutput. With Gülcin Albayrak,Ruud has requested EU funding,under the COST programme, for four workshops based on sub-jects identified by road-mapping.TC13 has initiated a programmeconcerned with the chemicalsleached from glass within theframework of exemption of glassproducts from the requirements of REACH registration; this potential links to TC02 activities.On the other hand, the work pro-gramme of TC25 (Modelling ofGlass Forming Processes) is cur-rently limited by the existence cur-rently of just two appropriate soft-ware packages.

Surfaces and Interfaces ClusterThe Surfaces and Interfaces cluster

is working actively on“Nanostructured Glasses” (TC16)using sol gel techniques whileTC24, “Coating on Glasses”, hasfocused on self cleaning glasses.TC19, “Glass Surface Diagnostics”,concentrates predominantly on ana-lytical techniques. These committeesadopt very different approaches,making interactions difficult, butthere is enormous potential in com-bining diagnostics with areas such asmedical and nano applications, and

Some participants of themeeting in Venice 2009

ICG art 1-04-2010 11:01 Pagina 57


with committees involved in chemi-cal durability such as TC02 andTC05. René Vacher stressed the needto think out of the box, as he put it, “New horizons need to be identified.”

Applications ClusterThe ‘Applications’ cluster, under

the Chairmanship of Richard Brow,covers: “Glasses for Medicine andBiotechnology” (TC04), concernedparticularly with the glass-mediainterface in medical applicationsand characterization methods;“Nuclear and Hazardous WasteVitrification” (TC05); and “Glassesfor Optoelectronics” (TC20).Applications are key to the impor-tance of Glass in Society andRichard Brow has identified manygaps in coverage within the currentlist. These committees also shouldlink strongly to other, more basiccommittees e.g. TC05 with TC02on “Chemical Durability andAnalysis” and TC18 on “Propertiesof Glass Forming Melts. A futureCTC focus will be the status ofsuch links and their development.

Communications ClusterThe ‘Communications’ cluster is

responsible for presenting the ICGand its activities to the broadercommunity. Exciting possibilitiesarise for Committee TC12 (Glass,Society and Environment) in areassuch as a blog to discuss the advan-tages of glass, and life cycle analy-sis. A round table discussion at thenext Congress in Brazil is also onthe cards. TC01 (Communications)and TC23 (Education and Training)are running successful workshopsfor students.

Summarizing the discussionsIn summarizing the discussions,

René Vacher proposed splitting thecluster entitled ‘Basics andProperties’, dropping ‘Surfaces andInterfaces’ as a separate Cluster andgrouping Technical Committeesunder the new headings: Basics;Properties; Characterization; Appli-

cations; Production and Informa-tion. Some lively discussions withthe Committee Chairs are expectedto follow.

New developmentsIn reporting new developments

already in place, René Vacher mentionedthat new TCs on Atomistic Modellingand Simulation (TC26 Chair: JohnMauro); Structure and Vibrations (TC27Chair: Bernard Hehlen) and Structure-Property Relationships (TC22 Chair:Georges Calas) were approved at the lastCouncil meeting. The SteeringCommittee has also set up an EditingSub-committee consisting of JohnParker (Chair), Renè Vacher, AliciaDuran and Cluster Coordinators, asrequired. In addition to defining policy forpublicity and encouraging theCommittees to publish their work, ithas taken on the specific task of generat-ing an update to the summary of ICGactivities last produced by Henk de Waalfor the 2000 Conference in Amsterdam.

Following the very successfulSummer School for new researchstudents held in Montpellier inMay 2009, the CTC consideredhow best to organize more suchevents. The feedback from the stu-dents and lecturers indicated that alonger, more focused meeting ofup to five days was needed, offer-ing extended opportunities fortutorial activities and studentinput. To maintain continuity asingle centre should be designatedfor these events and Montpellierwas accepted as a suitable venue.Additionally the CTC agreed tosupport single topic teachingactivities organized alongside ICGconferences and congresses.

The Steering CommitteeMeeting, chaired by the new ICGpresident, Fabiano Nicoletti,approved a proposal by AliciaDuran to co-finance a Bio-Glassesbook, edited by Alix Clare andJulian Jones. A specific programmefor financing an editorial plan andexpert meetings were presented atthe 2010 Steering Committeemeeting. Goals include: the pub-

lishing of an ICG historybook; an EFONGA finalreport; more press releases;and a booklet on ICG technol-ogy roadmapping.

The organizing of the ICG trien-nial congress is recognized as anhonour for the host nation and is amuch sought after privilege amongICG national members.

Arrangements are already in handfor the 2010 and 2013 events, butthe 2016 meeting currently hasthree candidate organizers. Newguidelines for selecting hosts havebeen drawn up to assist the SteeringCommittee in making its recom-mendations to Council. The docu-ment, entitled “The criteria forselecting locations for the ICGAnnual Meetings and InternationalCongresses” and edited by RolandLangfeld, was ratified.

THE 2010 ICG CONGRESSThe ICG Congress 2010 is to be

held from 15-19 September atPestana Hotel in Rio Vermelho,Salvador, Brazil. The SteeringCommittee will invite representa-tives of all three candidates for the2016 ICG Congress, the People’sRepublic of China, the UnitedKingdom and the United States, tomake oral presentations explainingthe reasons for their candidacy atthe Steering Committee andCouncil meetings in Brazil inSeptember 2010.

The Coordinating TechnicalCommittee and Steering Committeemeetings were held in Mainz,Germany, on 11 March 2010. ■

Inte

rvie

wMEETINGS

www.icglass.org

ICG art 1-04-2010 11:01 Pagina 58


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