HORN Glass Industries has successfully commissioned a next-generation all-electric melting furnace for Gerresheimer at its facility in Momignies, replacing an older electric unit with a significantly more efficient and flexible system.

The new Furnace F #4 represents a major technological upgrade, integrating HORN’s proprietary e-Fusion Power Boosting Technology. This system enhances electrical boosting efficiency within the melt, enabling improved heat distribution, faster refining, and reduced specific energy consumption. As a result, the furnace contributes directly to lowering CO₂ emissions while maintaining stable, high-output production.

Engineered for High-Quality Flint Glass Production

The furnace was designed by JSJ Jodeit GmbH, HORN’s specialist subsidiary for electric melting technologies. It is configured to produce high-quality flint glass for cosmetic container applications across multiple production lines, where optical clarity and homogeneity are critical.

A rectangular tank geometry was selected to optimise glass convection patterns. This design ensures uniform temperature distribution across the melt, minimising dead zones and improving fining efficiency. The result is enhanced bubble removal, better glass homogeneity, and more consistent forming conditions downstream.

Flexible and Renewable-Energy Driven Operation

The furnace operates entirely on electricity sourced from renewable energy, aligning with industry-wide decarbonisation targets. It also offers up to 50% flexibility in melting capacity, allowing Gerresheimer to adjust output in response to demand fluctuations without compromising efficiency or glass quality.

Advanced Furnace Design and Durability Features

The cold-top all-electric furnace incorporates several of HORN’s latest design innovations:

• A specially engineered furnace superstructure optimised for thermal stability
• Steelwork-integrated cooling systems that reduce thermal stress and extend campaign life
• An improved swivel electrode mechanism, allowing quicker and safer insertion and removal of top electrodes, reducing maintenance downtime

These features collectively contribute to longer furnace lifetime, improved operational reliability, and lower total cost of ownership.

Full Turnkey Scope and Integrated Systems

HORN executed the project on a full turnkey basis, covering:

• Furnace design and refractory engineering
• Supply of the steel structure and mechanical equipment
• Complete construction and installation works

In addition, the scope included several critical auxiliary systems:

• Emergency combustion system for backup operation
• e-Fusion power boosting system for enhanced melting control
• Advanced measuring and control instrumentation for precise process regulation
• Tank and throat cooling systems to stabilise critical furnace zones

Commissioning, Training, and Operational Readiness

The construction and heat-up phases were closely supervised by HORN’s specialist team to ensure controlled ramp-up and avoid thermal stress issues. The furnace was successfully brought online on October 3, 2025, without operational disruptions.

To ensure long-term performance, Gerresheimer’s operators underwent tailored technical training, enabling them to efficiently manage the furnace and its advanced control systems from day one.