Following a major fire in July 2025, Stoelzle Flaconnage Ltd moved quickly to restore production capacity at its Knottingley facility in the United Kingdom, appointing HORN Glass Industries on 29 August 2025 to carry out the time-critical cold repair and reconstruction of Furnace 1. The project required rapid execution and high-level coordination, with HORN assuming full responsibility for engineering, manufacturing, logistics and on-site implementation.
The rebuilt installation consists of a 170 tonnes-per-day end-fired furnace equipped with five forehearths. Despite the complexity of the scope, the entire project, from design and manufacturing through delivery, erection and commissioning, was completed in less than four months. This accelerated timeline was achieved through parallel workflows, allowing engineering, fabrication and installation activities to run simultaneously under closely coordinated project management.
Efficient logistics and streamlined on-site execution played a key role in maintaining the demanding schedule. Mechanical assembly, installation and commissioning were carried out with strict adherence to safety, quality and regulatory standards, ensuring operational reliability while minimising disruption to the site.
As part of the reconstruction, advanced technologies were integrated to improve sustainability and performance. The furnace includes the HORN e-Fusion electric boosting system, aimed at increasing energy efficiency and reducing COâ‚‚ emissions, alongside the HORN HRD-BEAM solution for contactless glass level measurement, supporting precise process control. 
HORN’s scope of supply covered complete engineering and execution of refractory materials, steel construction, melting furnace equipment, distributor systems, forehearths and batch charger, as well as dismantling works, cooling water supply, controlled heat-up, furnace filling and final commissioning.
By 20 December 2025, the furnace was fully operational again, allowing Stoelzle Flaconnage Ltd to resume production with minimal downtime. The project stands as a strong example of technical expertise, efficient collaboration and rapid industrial recovery, highlighting the capabilities of both teams in delivering complex glass manufacturing solutions under tight deadlines.
Source: HORN Glass with additional information added by Glass Balkan
