Forglass is pleased to announce a recent collaboration with Saint-Gobain Glass , successfully completing hot overcoating operations on a float furnace at one of their esteemed facilities in France. This project marks another significant partnership between our two organizations, reinforcing a shared commitment to operational excellence and technical precision within the glass manufacturing industry.

Saint-Gobain Glass, a globally respected leader in the production of high-performance, energy-saving coated glass and insulating glazing, sets a benchmark for comfort, efficiency, and safety. Their dedication to delivering superior products to their clients naturally extends to the rigorous standards they expect from their partners. Forglass is proud to meet these expectations, offering a comprehensive approach that aligns seamlessly with Saint-Gobain’s values.

A key factor in Saint-Gobain’s decision to entrust Forglass with this crucial project was our integrated methodology. This approach leverages deep engineering expertise and combines it with meticulous end-to-end project execution. In the demanding environment of a hot overcoating operation, this holistic approach is paramount to success.

Executing a hot overcoating project demands not only technical proficiency but also a profound understanding of the human element. The process necessitates the deployment of over 100 qualified professionals, operating in carefully managed short shifts. This critical safety measure ensures that personnel can perform their tasks effectively while allowing adequate recovery time, mitigating risks inherent in high-temperature environments.

Furthermore, the timing of hot overcoating is meticulously planned to minimize downtime between glass production cycles. This strict timeline leaves no margin for error; flawless execution is required from the very beginning. Forglass’s consistent ability to achieve this level of precision is a direct testament to the exceptional qualifications, unwavering dedication, and collaborative spirit of our entire team.

This successful partnership with Saint-Gobain Glass underscores Forglass’s capabilities in delivering complex, time-sensitive projects within the glass industry. We value the trust placed in us by a company with Saint-Gobain’s reputation and look forward to future opportunities to contribute to their continued success.

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This marks another important milestone for Horn, solidifying its position as a key player in the global glass industry.

The end-fired melting furnace is designed with a substantial melting area of 46 m2 and boasts a maximum daily output capacity of 120 tons per day (tpd). This robust design ensures efficient and reliable production of high-quality glass products.

The furnace will be equipped with three forehearths, enabling the production of container glass in a versatile range of colors, specifically flint, amber, and green. This multi-color capability allows the facility to cater to diverse market demands and offers greater flexibility in its product offerings.

Beyond the furnace itself, Horn will provide a comprehensive package encompassing design, engineering, equipment, and supervision of the construction works. This turnkey approach ensures a seamless and efficient project execution, minimizing potential disruptions and maximizing the facility’s operational readiness.

In line with a growing industry focus on sustainability, the furnace will incorporate several Horn E-Fusion Power Boosting systems strategically installed in the bottom of the melting tank. These systems are designed to reduce CO2 emissions during the glass melting process, contributing to a more environmentally friendly operation.

Further enhancing operational efficiency and product quality, the furnace will also feature the proven Horn HRD-BEAM. This innovative system utilizes contactless technology to measure the glass level with exceptional accuracy, maintaining a precision of +/- 0.1 mm. This precise measurement capability contributes to consistent glass quality and reduces waste.

The new glass manufacturing facility in Ashgabat is scheduled to commence operations in the third quarter of 2025. This project underscores Horn’s commitment to providing cutting-edge technology and comprehensive solutions to the glass industry, facilitating the production of high-quality glass products while promoting sustainable practices. The company’s expertise and integrated approach make them a valuable partner for companies looking to establish or expand their glass manufacturing capabilities.

Source: Horn with additional information added by GlassBalkan

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A super-boosted furnace for more sustainable production
Following the partial renovation of Furnace 3 in 2022, the complete renovation of furnace No. 1 at the Chalon-sur-Saône site is a key step in the modernization plan for this iconic plant in the Chalon basin. Specializing in the production of clear glass, furnace No. 1 produces iconic bottles from the Burgundy and Bordeaux regions, as well as specialty products for the spirits, still wine, and food markets, distributed locally, nationally, and internationally.

Thanks to this modernization, the furnace benefits from “super-boosted” technology, increasing the share of electricity in its energy mix. This now stands at 25 percent, thus reducing natural gas consumption to 75 percent. This development allows the Chalon-sur-Saône site to reduce its CO₂ emissions by 11 percent, while increasing its electrical melting power.

This is part of Verallia Group’s overall decarbonization strategy, which aims to reduce its CO₂ emissions by 46 percent by 2030 through the deployment of two new technologies: 100 percent electric furnaces, such as the one inaugurated in Cognac in September 2024, and hybrid furnaces planned for Spain in late 2025 and then in Saint-Romain-Le-Puy in 2026, reducing CO₂ emissions by 60 percent and 50 percent respectively.

Chalon-sur-Saône plant: 113 years of local anchorage and industrial expertise
Built in 1912, the Chalon-sur-Saône site is now the Verallia Group’s largest plant. With its 500 employees and three furnaces, the factory produces nearly a billion bottles each year. Recognized for its expertise in white glass, it notably produces the famous “dead leaf” colour, characteristic of Burgundy wines.

Source: Verallia France with additional information added by GlassBalkan

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Euroglas chose Glaston’s Roller Heat Control (RHC) upgrade to improve its tempering line performance as part of a series of investments to grow with its customers. “We aim to offer the width and depth of glass products they need to be their best partner,” says Frederik De Knijf, CEO of Euroglas in Belgium.

Euroglas serves the construction market in the Benelux countries with tailor-made glass. Founded in the 1960s, its broad glass portfolio strongly focuses on all interior glass types. The company also offers glass accessories, such as hinges and locks.

Expanding its operations, Euroglas acquired new production sites in the early 2000s and again in 2017. Today, it serves customers from three locations in Belgium – Meer, Fleurus and Bornem.

LARGEST TEMPERING FURNACE AT THE TIME

Euroglas co-invested in a first tempering furnace for its facility in Bornem in 1995 together with two other independent glass processors. In 2000, the same three partners joined forces again and purchased a Tamglass, now Glaston, ProE tempering furnace for the factory in Meer, just northeast of Antwerp. It was the largest tempering line in Benelux at the time. The company added a third tempering furnace, again from Glaston, when it acquired its production site in Fleurus.

In recent years, Euroglas has updated its machinery and product offering as part of a longer-term investment strategy.

UPGRADING PERFORMANCE

“In the past few years, we’ve replaced our core machines – the cutting, polishing, drilling and washing machines. But since tempering lines tend to wear less than equipment that is constantly in water, we decided to upgrade rather than replace our ProE,” De Knijf says.

The first driver for the upgrade was the ability to fully utilize the furnace bed, since the rollers no longer heated evenly. Especially larger glass sheets were prone to warp and other glass faults.

“The second driver was that we planned to start laminating. And to do that, we knew we needed A+ tempering quality. B+ wasn’t good enough,” De Knijf says.

The company chose Glaston’s RHC to bring Euroglas’s tempering furnace up to speed. They began the project at the end of 2023.

FULL BED UTILIZATION AND QUALITY ISSUES RESOLVED

“Our two goals have been achieved,” De Knijf says.

“Earlier, we could only use part of the furnace’s capacity, and we needed to run the furnace for about 16 hours. When we used the complete furnace bed, we had quality issues. Now, we are averaging 12 hours because we’re able to use its full capacity.”

And the quality issues have all been resolved – no more warping or surface defects like tempering marks.

QUALITY GLASS AND GOOD CUSTOMER FEEDBACK

The overall installation went well, and communication was smooth. “I would say it was a good, positive project,” De Knijf says. “We’re also currently considering the RHC for our other tempering furnace, although it is a smaller one.”

Customers have also given Euroglas positive feedback, saying they appreciate the improvement, especially with larger glass sheets. “When we ran a full-size 6 x 2.8 m glass sheet as part of our lamination line approval process, everything went smoothly. That was all the proof we needed!” De Knijf adds.

THE RIGHT TOOLS MAKE A DIFFERENCE

“Operators, too, have been very excited to use the upgraded tempering line. They no longer need to work magic to get the quality and quantity out of the furnace,” De Knijf describes. “It was too much trial and error before.”

Now operators have much more control over the furnace. With the new control panel, they can monitor the different zones to see exactly where the heat is. They can see the uniformity. The heat cameras show images of the heat distribution within the glass before it exits.

“With the right tools, our operators are much more motivated to do their jobs well,” he confirms.

GRADUAL GROWTH FORWARD

Euroglas plans to continue evolving over the years with its customers, gradually and steadfastly growing alongside them. “We will continue to challenge them – as they do us,” says De Knijf.

According to De Knijf, investing in quality equipment enables Euroglas to offer the full scope of glass products its customers need – helping the company strengthen its role as a trusted partner. “That’s why having first-class lines is so important,” he concludes.

Source: Glaston Corporation with additional information added by GlassBalkan

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The companies have joined forces to develop a novel hybrid furnace, a pivotal component of the Volta research project, which promises to drastically reduce carbon emissions and reshape glass production processes across the continent.

The inaugural ceremony for the pilot furnace, held in mid-February at AGC’s Barevka plant in Teplice, Czech Republic, marked a significant milestone. This first-of-its-kind furnace utilizes innovative technology expected to prevent the release of 192,500 tons of carbon emissions over the next ten years. To put this into perspective, this is equivalent to the annual emissions of over 35,000 European citizens, highlighting the potential for substantial environmental impact.

The Volta project, heavily supported by the European Commission, envisions a wider rollout of this technology across Europe. Estimates suggest that widespread adoption could cut emissions by over two million tons annually and reduce natural gas consumption by more than 10 terawatt hours. In a climate where energy security and environmental responsibility are paramount, these figures represent a monumental step forward.

Beyond emissions reduction, the Volta project also prioritizes circularity. The initiative includes the reconstruction of AGC’s Dubí production line, targeting a 50% electrification and 50% oxygen and gas-fired configuration. This hybrid approach will substantially reduce direct carbon emissions. Moreover, the Volta hybrid melting furnace is engineered to operate with a significantly higher ratio of recycled materials, further minimizing its environmental footprint and promoting resource efficiency.

AGC president and CEO Yoshinori Hirai emphasizes the transformative nature of the project, stating that the new hybrid line will “not only significantly reduce carbon emissions but will also increase the energy efficiency of our production.” He further positions the Volta project as a “major step on our journey toward carbon neutrality,” underscoring AGC’s dedication to innovation and sustainability.

The partnership between AGC and Saint-Gobain, culminating in the Volta project and its innovative hybrid furnace, presents a promising model for the future of the flat glass industry. By prioritizing emissions reduction, energy efficiency, and circularity, this initiative paves the way for a more sustainable and environmentally conscious approach to glass manufacturing, setting a powerful precedent for other industries to follow. The project’s potential to significantly curb carbon emissions and reduce reliance on natural gas makes it a critical development in Europe’s pursuit of a greener future.

Source: AGC with additional information added by GlassBalkan

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This highly anticipated biennial event will be held at the scenic Wellness Hotel Horal mountain resort in Velke Karlovice, Czech Republic.

This seminar provides a crucial platform for over 150 glass experts from across the globe to convene and delve into the latest advancements in simulation and control tools. The core objective remains consistent: to optimize the efficiency, effectiveness, and sustainability of glass melting and forming processes.

Attendees can expect in-depth discussions and presentations covering a wide array of topics, all centered around leveraging simulation and control techniques. For a comprehensive list of specific topics, please visit the Glass Service website at www.gsl.cz.

Call for Abstracts:

The seminar organizers are currently soliciting abstracts for presentation. This is a valuable opportunity to share your research, insights, and practical applications with leading professionals in the glass industry. The deadline for abstract submission is February 28th. To submit your abstract, please email it to seminar@gsl.cz.

Key Takeaways:

Event: 17th International Seminar on Furnace Design – Operation and Process Simulation
Dates: June 18-19, 2025
Location: Wellness Hotel Horal, Velke Karlovice, Czech Republic
Organizer: Glass Service
Focus: Simulation & control tools for optimizing glass melting and forming
Abstract Deadline: February 28th
Abstract Submission: seminar@gsl.cz
Topic Details: www.gsl.cz

Registration for the seminar will open in April 2025. We encourage all interested professionals to mark their calendars and plan to attend this vital event for the glass industry. Stay tuned for further updates regarding registration and the finalized program. We look forward to seeing you in Velke Karlovice!

Source: www.gsl.cz with additional information added by GlassBalkan

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Source: Horn Glass Industries with additional information added by GlassBalkan

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Determined to build an even more competitive business, the company is positioning its Holzminden, Germany, plant for a strong future by undertaking efforts to make the facility leaner, more agile and more efficient. The upgrade will also include the installation of cutting-edge furnace technology that is expected to significantly enhance energy efficiency and reduce emissions.

In combination with the also-planned on-site oxygen production, this comprehensive technology upgrade supports the conversion of an existing furnace to a Gas-Oxy system. The innovative set-up is expected to reduce fuel consumption by up to 30 percent and lower CO2 emissions by approximately 4,000 tonnes annually compared with current technology.

“O-I has been making glass for our customers for over 120 years and is a trusted, high-quality packaging provider to brands around the world,” said Randy Burns, Chief Administrative & Sustainability Officer for O-I. “We are working with innovative suppliers as we seek to deploy top-glass-making technologies to create new value by driving decarbonization at O-I, increasing productivity, and supporting our customers in their own decarbonization efforts.”

Source: O-I Glasswith additional information added by GlassBalkan

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This partnership involves the supply and installation of a cutting-edge, energy-efficient glass melting furnace equipped with three forehearths for Ambev’s new container glass plant in Carambeí, Brazil.

This project represents a considerable milestone, marking the *third* furnace HORN has provided to Ambev, a testament to the enduring trust and successful partnership between the two companies. The continued collaboration highlights HORN’s commitment to delivering high-quality, sustainable solutions to the beverage industry and Ambev’s dedication to investing in advanced manufacturing capabilities.

The new furnace will play a crucial role in producing glass containers for Ambev’s portfolio of iconic brands, including Stella Artois, Beck’s, and Spaten, supporting breweries across Brazil. The facility’s emphasis on energy efficiency underscores Ambev’s commitment to environmental sustainability and aligns perfectly with HORN’s focus on developing environmentally responsible technologies.

Construction at the Carambeí site is progressing rapidly. Beginning in late January, HORN’s experienced team of engineers and technicians will be on-site to oversee and support the installation process, ensuring a seamless and efficient integration of the new furnace. Their expertise will be crucial in guaranteeing optimal performance and minimizing downtime.

HORN is confident in delivering a successful project, further strengthening its partnership with Ambev. This collaboration showcases the mutual dedication to innovation and sustainability within the container glass industry, setting a benchmark for future advancements in environmentally conscious glass production. The project’s successful completion will not only enhance Ambev’s production capacity but also contribute to a more sustainable future for the beverage industry in Brazil and beyond.

Source: Horn Glass Industries with additional information added by GlassBalkan

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This initiative centers around a hybrid end-fired regenerative furnace, a technological advancement poised to significantly reduce the carbon footprint of glass production while maintaining exceptional product quality.

The core of the BEAR project is a revolutionary hybrid furnace capable of utilizing up to 40% electricity for its heat supply – a substantial leap from the industry standard of 5-10%. This innovative approach drastically reduces reliance on natural gas, achieving a 50% reduction in natural gas consumption for the melting process compared to Best Available Technologies. This translates to a projected avoidance of over 100,000 tonnes of CO2 equivalent emissions over the next decade – an environmental impact equivalent to offsetting the annual greenhouse gas emissions of 20,000 households in the Zasavje region of Slovenia.

This achievement is particularly significant given the BEAR project’s status as the first and only initiative in Slovenia to receive co-funding from the EU Innovation Fund, underscoring the project’s innovative nature and its contribution to the European Green Deal. The €3,730,000 project, with 60% financed by the EU Innovation Fund, demonstrates a strong commitment to sustainable industrial transformation.

Further enhancing its sustainability profile, the hybrid furnace will be integrated into a hybrid energy storage system, working in conjunction with locally available photovoltaic power plants. This collaboration, part of the Horizon Europe i-STENTORE project, further strengthens the project’s commitment to renewable energy integration and aligns production with the availability of sustainable energy sources. This proactive approach ensures adaptability to the evolving demands of a sustainable energy future.

Hrastnik1860’s commitment to sustainability extends beyond the BEAR project. Over the past three years, the company has expanded its own photovoltaic capacity by 1.3 MWp and transitioned entirely to 100% clean electricity sourcing. Looking ahead, Hrastnik1860 plans to further increase its reliance on locally sourced renewable energy and actively encourages the development of energy communities to foster energy independence and resilience. The company clearly positions clean glass melting as a central pillar of its broader sustainability strategy, showcasing its leadership in the decarbonization of the European glass and energy-intensive industries.

Source: Hrastnik1860 with additional information added by GlassBalkan

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