Batch and cullet melting represent the initial stages of the glass melting process. The stability of this process, influenced by factors such as pull, cullet level, glass color, raw material variations, rheological behavior, and the batch charger, is crucial for ensuring optimal glass quality in gas-fired furnaces. The potential instability necessitates continuous 24-hour monitoring and potential corrective control to minimize quality issues. Additionally, the increasing electric boosting levels resulting from the decarbonization process have the capacity to alter glass convection loops, displacing batch downstream in the process.

In cold top melting furnaces, the thickness of the batch plays a pivotal role in insulating the hot glass melt and minimizing heat loss. However, variations in pull and cullet can significantly impact batch thickness. Until now, there has been a lack of systems capable of measuring the actual batch thickness or height and incorporating this parameter into automatic model-based predictive furnace control.

This paper will present the latest developments and results for both gas-fired and cold top electric smelters.

Artificial Intelligence is present in our everyday life. But what are the main benefits of AI in industry for real needs of glassmakers?

Thanks to the standardization of communication protocols on a production line, the interoperability of robots allows an exchange of information. Thanks to deep learning techniques in intelligent inspection robots, it is now possible to anticipate production trends in addition to an accurate detection and categorization of defects. IRIS intelligent solutions can thus increase productivity by highly accurate defect identification, managing the settings optimization and integrating the production trends prediction. Decreasing the dependence on human factor is a key goal of IRIS AI-based strategic developments.

Since over 95 years Agr International, Inc. is strongly engaged in research and development dedicated to providing solutions that help improve the quality, safety and efficacy of the packaging we are relying on in our daily life.

We have seen an evolution in solutions from mechanic to electric then to electronic and computer controlled solutions. The common denominator was however always the need for the operator to set-up the machines according to the requirements as well as the tested glass bottle or jar.

With faster processing power and innovative algorithms Agr was able to change the archaic way of measurement set-up to an automatic solution and assisting in reaching sustainability goals with measurement solutions but also in analyzing and optimizing the design of the container.

The presentation will feature approaches on Product Sustainability through Lightweighting as well as Process Sustainability through at the Line Monitoring and generation of actionable data as a base for Industry 4.0 and KI.

Examples will include financial gains as well as a CO2 reduction through lightweighting and a reduction of Carbon Footprint due to the generation of fast actionable data.

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Reliable and high performing machines are the basis for a modern and highly efficient glass plant. This is essential to remain competitive.

With Heye’s many years of knowledge in glassmaking, we offer you a wealth of expertise to achieve this. Comprehensive and preventive maintenance concepts as well as global service network are just one area of our extensive range of services to increase the performance of a glass plant. Whether new equipment or refurbished, modernised equipment, Heye the right partner at your side.

Tiama now offers high-speed inspection with AI in all its sidewall machines. With its fleet of sidewall machines running with AI, Tiama leverages the throughput and the production quality of plants.

Sébastien Ying, VP APAC at Tiama will present some plants’ use cases where its implementation reduced the false reject rate whilst improving the critical defect detection capacity at the same time. You will also understand how the technology can be implemented into existing sidewall machines.

The glass industry is energy intensive with high emissions and operating costs. Green solutions are now available to glass manufacturers, including electric and hybrid furnace technology. The choice of technology depends on the project requirement, each option imposing restraints as well as benefits. All-electric melting provides the most energy efficient solution yet cannot be easily applied to some glass types; hybrid furnaces provide greater flexibility at the expense of zero emissions.

The paper will present the benefits and challenges of the all-electric melting technology implemented by Fives at Verallia’s Cognac plant in 2024 and an analysis of the hybrid technology.

The glass moulding process using IS machines for jars and bottles is the cornerstone of container glass production. This high-speed operation demands precision, as even minor defects are identified by rigorous quality inspection systems. Compressed air and vacuum are crucial in shaping the glass gob, ensuring it fills the mould cavity completely by displacing air.

In glass factories, compressors and vacuum pumps are often the largest consumers of electrical power, aside from electric furnaces. In an era of heightened environmental consciousness and carbon footprint awareness, selecting energy-efficient compressors and pumps is critical to reducing CO2 emissions and optimizing energy consumption.

Sustainability extends beyond energy efficiency: with furnaces designed for a lifespan of up to 20 years, auxiliary equipment must also meet long-term durability and performance standards. High-quality machinery, backed by extended warranties and well-defined maintenance plans, significantly reduces downtime and costly repairs, supporting both operational efficiency and environmental goals.

The industry is increasingly prioritizing Total Cost of Ownership (TCO) over low upfront costs. Investing in robust, energy-efficient equipment minimizes environmental impact, aligning economic benefits with ecological responsibility - a decisive shift for a sustainable future in glass manufacturing.

With hot end sensing and robotics new possibilities for glass making are within reach. In addition, with Data Science and AI more new opportunities are unlocked. XPAR Vision continues to invest in these technologies.

During the presentation learnings will be shared and examples given. Based on these learnings it is concluded that combining AI and data driven KPI’s allow for setting new standards for glass manufacturing, defined by actionable data leading to improved forming process control and optimization. As such allowing for future-proofing glass making.

With the GIZAZ glassworks project in Qatar, Falorni Tech has fully expressed its engineering and construction capabilities. From the initial stages of the project, the glassworks faced challenges due to limited space in relation to production capacity.

However, these constraints did not result in compromised solutions; instead, they led to the development of a modern facility that fully meets the customer's specifications and expectations.

In this presentation, we will provide an overview of the design criteria and technical solutions implemented, highlighting the various construction phases leading up to the startup of the plant.

Tecsiglass Srl, headquartered in Genoa (Italy), launched some R&D innovative projects in partnership with the University of Genoa and the research Company Sirelab.

Two major research pillars are the following:

• CFD simulations
• Software Platforms

CFD modelling is applied to some areas such as:

• Combustion simulation for studying the effects of furnace design parameters on flame development
• Boosters and boilers positioning
• Effects of electrodes layout (position) and voltage on melted glass flow structures and residence time
• flow and heat transfer inside regenerative chambers
• furnace aging by use of the patented tool FurnEx®
• Software platforms applied to the above modelling systems. Namely:
• FURNEX – APP for furnace erosion analysis
• Virtual reality for personnel training purposes.