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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Horn, a recognized leader in flat glass equipment manufacturing, will be supplying a state-of-the-art solar glass furnace to Glass Technology’s new production facility in the United Arab Emirates (UAE).

Source: Glass Technology with additional information added by GlassBalkan

The post Horn to Supply Cutting-Edge Solar Glass Furnace to Glass Technology’s New UAE Facility appeared first on GlassBalkan.

Source: Horn Glass Industries with additional information added by GlassBalkan

The post Glass Technology and HORN Forge a Solar Future in the UAE with Groundbreaking Low-Iron Glass Facility appeared first on GlassBalkan.

Source: Horn Glass Industries with additional information added by GlassBalkan

The post Gerresheimer Invests in Low-CO2 Future with New Hybrid Oxyfuel Furnace from HORN appeared first on GlassBalkan.

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 cutting-edge solution is uniquely designed to meet the demanding requirements of high-pull forehearths and the stringent temperature homogeneity (THI) standards needed in non-nucleaic pressed and blown (NNPB) glass production.

Advanced Technology for Superior Performance

The GCS® 301-advanced system stands out due to its integration of the most advanced technology in forehearth design. One of its key features is the specially designed cover block, which incorporates both direct and indirect centerline cooling mechanisms. This innovative approach allows for precise temperature control across various sections of the forehearth, enhancing the quality of the glass produced.

The ability to separate areas along the control zones into two boundary regions is particularly notable. This configuration enables the system to effectively heat the glass while simultaneously directing cool air to a centralized section. As a result, manufacturers can achieve optimal thermal conditions, ensuring consistent glass quality and minimizing defects.

Flexibility and Efficiency

Flexibility is a core principle behind the GCS® 301-advanced. The system is equipped with a left/right heating configuration that adapts to a variety of production needs. This adaptability is essential for modern glass producers facing fluctuating production demands and the need for rapid changeovers. The system’s design not only supports high-pull operations but also enhances overall productivity.

Moreover, the use of high-performance insulating refractories in the GCS® 301-advanced contributes to powerful glass conditioning. These insulating materials are engineered to enhance thermal retention and improve energy efficiency, thereby reducing operational costs and environmental impact. In an industry where every percentage point of energy savings can translate to substantial financial benefits, this innovation is a game changer.

Design

• The GCS® Series 301-advanced design allows a wide range of gob temperatures to produce a variety of different sized articles
• Special cover block design for area separation along the control zones:
• Separated boundary areas to heat the glass particularly at the sides of the forehearth
• Separated central section to guide direct cooling air
• Improved thermal homogeneity through optimized transition between equalizing zone and spout
• Superstructure design with direct & indirect centreline cooling
• Use of high-performance insulating refractories
• Powerful glass conditioning

Features

• High thermal homogeneity (THI) for flint glass and coloured glass (including HORN forehearth boosting)
• Refractory can be designed for additional HORN equipment like: Stirrers, VARI-DRAIN® or forehearth boosting
• High flexibility
• Wide range of production processes

Source: HORN Glass’with additional information added by GlassBalkan

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In response to this challenge, HORN is taking significant strides forward, positioning itself at the forefront of the industry’s decarbonisation efforts. With a strong commitment to climate-neutral packaging, HORN has developed and evaluated hybrid furnace technology as a promising solution to reduce carbon dioxide emissions in glass production.

Understanding Hybrid Furnaces

Hybrid furnaces represent a groundbreaking innovation in glass manufacturing, aiming to replace a substantial portion of the natural gas traditionally used in the melting process with electricity. HORN defines a hybrid furnace as any system that combines electric power with fossil fuel, thus requiring both energy sources for optimal operation. Depending on the specific design of the furnace, the electric contribution can vary widely, ranging from 20% to as much as 80%.

This flexibility allows manufacturers to adapt their energy inputs to meet varying production needs while significantly curbing emissions. In particular, the combustion architecture of HORN’s hybrid furnaces, which features strategically placed oxygen burners along the side walls, enables precise control of temperature distribution. By dynamically adjusting gas distribution, operators can optimize the energy usage in different sections of the furnace. For example, when a higher electric share is utilized, the gas distribution can be redirected predominantly towards the refining area, with melting primarily powered by electrodes. This innovative configuration enhances energy flexibility well beyond that of traditional Hybrid End Fired Furnaces.

Environmental Impact and Efficiency

One of the most compelling advantages of HORN’s hybrid furnaces is their potential to drastically reduce CO2 emissions in the glass melting process. With configurations allowing for operation with up to 80% electric power, manufacturers can achieve a reduction of CO2 emissions by up to 50% compared to conventional fossil-based oxyfuel furnaces during the melting phase.

This technology not only addresses the environmental impact but also enhances operational efficiency. The hybrid furnaces are characterized by several key features:

– Low Carbon Footprint: Substantial reduction in greenhouse gas emissions compared to traditional methods.
– Electric Energy Input Up to 80%: Significant flexibility in energy sourcing allows for optimized operational efficiency and sustainability.
– Flexibility of Electric Boosting: Operators can adapt energy inputs to enhance performance based on production needs.
– High Glass Quality: Maintaining product integrity while utilizing diverse energy sources.
– Low Specific Energy Consumption (< 3 GJ): More efficient energy use translates to cost savings and reduced environmental impact.

Join HORN at Glasstec 2024

As the glass industry leans towards sustainable practices, HORN is proud to showcase the future of glass melting technology. At Glasstec 2024, HORN will present its latest innovations in the form of Hybrid Furnaces, Super Hybrid Furnaces, and All Electric Furnaces. We invite you to discover the transformative possibilities of using electrical energy in glass production by visiting our booth C32 in hall 13.

By embracing such innovative technologies, HORN is not only advancing its own capabilities but also contributing significantly to the glass industry’s collective goal of achieving climate neutrality. Together, we can pave the way towards a more sustainable and responsible future in glass manufacturing.

Source:Horn Glass Industries with additional information added by GlassBalkan

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This cutting-edge technology utilizes radar technology for contactless measurement, guaranteeing precise control and enhanced efficiency in glass melting processes.

Maintaining a constant glass level is crucial for smooth operation in glass furnaces. Fluctuations can disrupt the furnace’s stability and significantly impact gob weight, ultimately affecting the quality of the final product. The HORN HRD-BEAM system tackles this challenge head-on, offering exceptional accuracy of +/- 0.1 mm or better. This level of precision allows for precise control of the glass level, seamlessly integrating with all common charging machines.

The benefits of HORN’s contactless approach extend beyond accuracy. The system minimizes maintenance requirements due to the absence of mechanical moving parts, leading to reduced downtime and operational costs. Furthermore, the radar technology is unaffected by factors like glass color, cooling air, or the need for spill air, further simplifying operation and maximizing efficiency.

Key Features of the HORN HRD-BEAM System:

Contactless Measurement: Eliminates the need for physical contact, ensuring accurate measurement without compromising glass integrity.
Simple Installation: Easy integration into existing furnace systems, requiring no welding, for a streamlined installation process.
Network Connectivity: Remote access capabilities for convenient monitoring and system management.
Minimal Maintenance: Reduced maintenance demands due to the lack of moving parts, minimizing downtime and operational costs.
Versatility: Adaptable to both container and float glass furnaces, providing a universal solution for various applications.

The HRD-BEAM system has already gained significant traction within the industry, with seven units sold in 2023 and four more in 2024. This rapid adoption showcases the industry’s confidence in HORN’s technology and its ability to deliver tangible improvements in efficiency and production quality.

HORN invites you to experience the transformative power of radar measurement technology at glasstec 2024. Join us to learn how the HRD-BEAM system can optimize your furnace operations, enhance glass quality, and drive profitability for your business.

Source:Horn Glass Industries with additional information added by GlassBalkan

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HORN Glass Industries exemplifies this principle with its extensive network of subsidiary companies located across the globe. With operations in China, Malaysia, India, Croatia, Ukraine, the Czech Republic, and Brazil, HORN ensures that it can provide timely support and services to its customers, no matter where they are located.

Despite this global presence, HORN Glass Industries maintains a strong operational hub at its headquarters in Plössberg, located in the picturesque Bavarian Upper Palatinate region of Germany. Here, approximately 90 percent of the company’s products are manufactured and exported to over 75 countries worldwide. This strategic approach allows HORN to leverage its central location while still meeting the diverse needs of its international clientele.

A Comprehensive Overview

To gain a deeper understanding of HORN Glass Industries, a bird’s eye view of the company premises reveals the intricate layout and functionality of its facilities. A recent video showcases the various departments housed within the buildings, illustrating the seamless integration of engineering, production, and administrative functions. This visual representation not only highlights the scale of HORN’s operations but also emphasizes its commitment to quality and innovation.

The company’s focus on research and development is evident in its state-of-the-art facilities, where skilled professionals work diligently to advance glass manufacturing technologies. HORN’s investment in cutting-edge machinery and processes ensures that it remains at the forefront of the industry, providing customers with high-quality products that meet the evolving demands of the market.

Global Reach with Local Expertise

HORN Glass Industries’ subsidiaries play a crucial role in enhancing the company’s global reach. Each location is staffed with local experts who understand the specific needs and preferences of their regional markets. This localized approach not only fosters strong relationships with clients but also enables HORN to respond swiftly to market changes and customer inquiries.

By strategically positioning its subsidiaries in key regions, HORN can effectively manage logistics and supply chains, minimizing lead times and ensuring that customers receive their products promptly. This responsiveness is a cornerstone of HORN’s business model, reinforcing its reputation as a reliable partner in the glass manufacturing sector.

Source:HORN Glass Industries with additional information added by GlassBalkan

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The project, which faced a brief delay due to the tragic earthquake in 2023, was successfully commissioned in June 2024.

The order for Furnace B was placed by Baştürk Cam in 2021. The furnace, designed for a melting capacity of 560 tonnes-per-day, boasts an impressive melting surface of 185.4 square metres and includes six forehearths for the production of container glass. Powered by natural gas or backup diesel oil burners, the furnace will enable Baştürk Cam to meet its growing production demands.

HORN’s scope of supply for this greenfield project was comprehensive, encompassing the engineering of the refractory and steel structure, the combustion system, boosting system, measuring and control equipment, and a HVR® 600F batch charger developed by HORN. The company also provided a NIR furnace camera and supervised the erection, heat-up, and commissioning of the furnace.

Despite the temporary setback caused by the 2023 earthquake, the project was ultimately completed with great success. On June 2, 2024, Baştürk Cam celebrated the first glass produced by the new furnace, which is designed to manufacture flint-colored container glass.

This landmark project is a testament to HORN’s expertise in glass melting technology and its ability to deliver innovative solutions that meet the evolving needs of the glass industry. By partnering with Baştürk Cam, HORN has strengthened its presence in the Turkish market and reinforced its position as a trusted global leader in the field of glass production.

Source:Baştürk Cam with additional information added by GlassBalkan

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