Vol. 6 | No. 1 | April - June 2018

Quarterly Journal of The All Manufacturers’ Federation Bi-lingual

Special Feature

• Drawing Competition - Adopt a Glass Bottle • Soda Ash for Glass Manufacturing • Opportunities and Challenges posed by the Environment for the Glass Industry in India • The Glass Industry Waking up to its Needs • Hot Sealing of Aluminium Films on Glass Containers • Safety Considerations of Architectural Glass • Float Glass Process and Applications – Revisited: Part I • Life Cycle Analysis (LCA) of Container Glass in India – 2017 • Cold End Project between the Ganges and Rivers • Indian Pharmaceutical Plants serve the World • Float Glass Process Technology – Revisited: Part II • Raising our to the Glass Industry

Upcoming Events - Aug 17 (Details on page # 22) • Interactive Session on Industry- related Risk and Opportunities • Ist AIGMF Glass Awards • Annual General & Executive Committee Meetings 1st Prize (winning entry) of Drawing Competition on ‘Adopt a Glass Bottle’ held on World Environment Day - June 5, 2018

812 NEW HOUSE, 27 BARAKHAMBHA ROAD, -110001, INDIA Telephone: + 91 11 23316507 Fax: + 91 11 23350357 E-Mail: [email protected] Website: www.aigmf.com

812 NEW DELHI HOUSE, 27 BARAKHAMBHA ROAD, NEW DELHI-110001, INDIA Telephone: + 91 11 23316507 Fax: + 91 11 23350357 E-Mail: [email protected] Website: www.aigmf.com GLASS MELTING GLASS FORMING

We provide integrated oxyfuel technology using We provide low cost, compact and modular cost effective on-site oxygen generators based hydrogen generators using SMR technology on VSA technology and suitable combustion capable of producing ultra high purity system to maximise performance, enhance (99.999%) gas required for glass manufactur- productivity and decrease emissions in glass ing process. melting process.

B-802, Lotus Corporate Park, Off Western Express Highway, Goregaon (East) - 400063, Maharashtra, India [email protected] | +91- 22 6682 0000 | www.nishalgroup.com 2 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com

Acting President RAJ KUMAR MITTAL Vice President BHARAT SOMANY Hon. General Secretary SANJAY AGARWAL Hon. Treasurer K C JAIN Member Editorial Board A K BANDYOPADHYAY Quarterly Journal of THE ALL INDIA GLASS MANUFACTURERS’ FEDERATION Former Principal, Govt. College of Engineering & Ceramic Technology-GCECT, Kolkata DEVENDRA KUMAR Prof. & HOD, Dept. of Ceramic, Indian Institute of Technology (Banaras Hindu University) Vol. 6 | No. 1 | April-June 2018 K K SHARMA President, NIGMA and Plant Head, HNG Neemrana,

MEMBER ASSOCIATIONS EASTERN INDIA GLASS MANUFACTURERS’ ASSOCIATION (EIGMA) c/o La Opala RG Ltd. Contents Chitrakoot, 10th Floor, 230 A A.J.C. Bose Road Kolkata - 700 020 President - Sushil Jhunjhunwala From Acting President's Desk 5 NORTHERN INDIA GLASS MANUFACTURERS’ ASSOCIATION (NIGMA) c/o Hindustan National Glass & Industries Ltd. Post Office - Bahadurgarh, Jhajjar, Haryana-124 507 Drawing Competition - Adopt a Glass Bottle 7 President - KK Sharma Vice President - Jimmy Tyagi Advertise in Kanch 10 Honorary General Secretary - NN Goyal Secretary & Treasurer - JB Bhardwaj SOUTH INDIA GLASS MANUFACTURERS’ ASSOCIATION (SIGMA) Soda Ash for Glass Manufacturing 11 c/o AGI glaspac (An SBU of HSIL Ltd.) Glass Factory Road, Off. Motinagar Glass News 14 PB No. 1930, Sanathnagar, PO Hyderabad -500 018 President - Sandip Somany GLASS MANUFACTURERS’ SYNDICATE (UPGMS) Interactive Session on Industry-related Risk and Opportunities; c/o General Traders AIGMF Glass Awards & 22 A-10, Industrial Estate, Firozabad – 283203 (UP) Executive Committee / Annual General Meetings (Aug 17) President - Raj Kumar Mittal Vice President - Dharmendra Mohan Gupta List of Advertisers 22 Vice President - Santosh Agarwal Hony. Secretary - Sanjay Agarwal Treasurer - Deepak Gupta Opportunities and Challenges posed by the Environment for the 23 Jt. Secretary - Pramod Kumar Garg Glass Industry in India WESTERN INDIA GLASS MANUFACTURERS’ ASSOCIATION (WIGMA) c/o Empire Industries Ltd.- Vitrum Glass The Glass Industry Waking up to its Needs 25 Empire House, 2nd Floor, 414 S.B. Marg Lower Parel, Mumbai - 400 013 President - G K Sarda Hot Sealing of Aluminium Films on Glass Containers 27 Honorary Secretary - Naresh Gupta

Quarterly Journal of Glass Industry, published and printed by Safety Considerations of Architectural Glass 31 Vinit Kapur on behalf of The All India Glass Manufacturers’ Federation from 812, New Delhi House, 27 Barakhamba Road, New Delhi – 110001 Float Glass Process and Applications – Revisited: Part I 36 and printed at New United Process, A-26, Ph-II, Naraina Indl. Area, New Delhi-110028 Life Cycle Analysis (LCA) of Container Glass in India – 2017 41 T:+91 11 2331 6507 F:+91 11 2335 0357 E: [email protected] Editor MOHAN LALVANI Cold End Project between the Ganges and Yamuna Rivers 43 Complimentary copy for Members / Government Departments / NGO's and those connected with Glass Industry Indian Pharmaceutical Plants serve the World 44 Others: Price (excluding bank charges): Indian Companies : ` 125 per copy Float Glass Process Technology – Revisited: Part II 47 Annual Subscription ` 450 Foreign Companies : US$ 25 per copy Membership of The AIGMF 50 Annual Subscription US$ 80 About The AIGMF 51

Raising our Glasses to the Glass Industry 53

www.glassworldwide.co.uk Kanch | Vol. 6 | No. 1 | April-June 2018 3 812 NEW DELHI HOUSE, 27 BARAKHAMBHA ROAD, NEW DELHI-110001, INDIA Telephone: + 91 11 23316507 Fax: + 91 11 23350357 E-Mail: [email protected] Website: www.aigmf.com www.aigmf.com

From Acting President’s Desk

Series of Events were organized by Glass Industry ahead of World Environment Day. The All India Glass Manufacturers Federation (AIGMF) with the help of Education Department, Govt. of NCT of Delhi invited online entries from children between 7-16 years to participate in “Drawing Competition” on the theme “Adopt a Glass Bottle”. Former Presidents, Mr. Sanjay Somany and Mr. S C Bansal were jury members who adjudged top 3 drawings out of 2000+ entries received from all over India. 1st prize (Rs. 5,000) was given to Triman Dua aged 7 years, 2nd class student of Lancers Convent School, Prashant Vihar, Delhi; 2nd Prize (Rs. 2,000) was given to Riddhima Gupta aged 10 years, 5th class student of Delhi Public School, Rohini, Delhi and 3rd Prize (Rs. 1,000) was given to Rahul Kumar Kamat aged 13 years, 9th class student of Govt. Co-Ed Secondary School, Sector 15G, Rohini, Delhi. Parallel to Ex Com meeting on May 26th, a special session on Soda Ash for Glass Manufacturing was organised wherein Ms. Marguerite Morrin, Executive Director Chemicals, IHS Markit, London was invited as guest speaker who gave presentations on Global Overview on Soda Ash and Soda Ash & the Environment. Ms. Morrin said that Soda Ash is used in Glass Manufacturing, which is produced both naturally as well as in chemical form. Ms. Morrin, covered following main topics in her presentation, Top producers, Global Supply Profile, Capacity Changes by Type and by Geography, Soda Ash & the Environment, Natural Soda Ash, its place in the Global Soda Ash Industry, New Environmentally focused demand sectors e.g. lithium carbonate, solar panels. A glass bottle (specially manufactured by Hindustan National Glass and Industries Ltd.) with World Environment Day and Swachh Bharat Abhiyaan logos was launched enabling people demand responsible and safe packaging. A short video was released in on 'Benefits of Glass Packaging'. This video is in addition to English version released in early 2018. AIGMF also released an update on Life Cycle Assessment (LCA) Study of “Container Glass” in India. This update was done for its earlier study released in 2012, which provides the foundation for meaningful use of LCA results and to portray green image of the product amongst consumers and other stakeholders. Alongside Annual General and Executive Committee Meetings, AIGMF is organising an Interactive Session on Industry-related Risk and Opportunities on August 17 at Hotel Pride Plaza, Aerocity, Near T3 Terminal, Delhi. The session will cover presentations on Environment Law by Mr. Nawneet Vibhaw, Associate Partner, Khaitan & Co.; Competition Law by Mr. Manas Kr. Chaudhuri, Partner, Khaitan & Co., and Anti-Dumping/Indirect Tax by Mr. Kabir Bogra, Partner (Indirect Tax) Khaitan & Co. I extend invitation to all members to participate in these events

Raj Kumar Mittal Acting President AIGMF; President U.P. Glass Manufacturers' Syndicate (UPGMS) and Owner, Mittal Ceramics 812 NEW DELHI HOUSE, 27 BARAKHAMBHA ROAD, NEW DELHI-110001, INDIA Kanch | Vol. 6 | No. 1 | April-June 2018 5 Telephone: + 91 11 23316507 Fax: + 91 11 23350357 E-Mail: [email protected] Website: www.aigmf.com AGI glaspac…..Delighting customers since 1972

Experience purity in every sip ! ENABLING COLOURS….., ENABLING GLASS….

Through colouring forehearth technology, we PACKAGED can produce coloured glass TO CHILL ! containers suiting the brand Delightingrequirements customers since 1972 AGIAGI glaspac….. glaspac…..Delighting customers sinceAGI: 1972glaspac Largest manufacturer of wine bottle AGI glaspac…..Delighting customers since 1972 in Green, Flint, Amber and coloured glass.

Preserving authentic OliveExperience Oil…, purity in every sip ! Experience purity ENABLING COLOURS….., Experience purity AGI glaspac: Largest ENABLING GLASS…. in every sip ! manufacturer of Beer bottle in ENABLING COLOURS….., in every sip ! Flint, Amber and Green glass ENABLINGENABLING GLASS…. COLOURS….., ENABLING GLASS….

Through colouring forehearth technology, we PACKAGED can produce coloured glass TO CHILL ! containers suiting the brand requirementsAGI glaspac: Leading manufacturer of container glass AGI: glaspac Largest manufacturer of wine bottle Through colouring in Green, Flint, Amber and coloured glass. forehearth technology, we AGI glaspac: Largest manufacturer of AGI glaspac: Leading manufacturer of glass jar can produce coloured glass AGI glaspac: LeadingPACKAGED manufacturer of range of and bottes with product range 28ml to 4000ml Preserving authentic Olive Oil…, soft drink bottles in Flint, Amber and Pharma and Chemical bottles capacity…, Various Shapes …,Neck Finishes.. containers suiting the brand Through colouringGreen glass with Applied Ceramic Our range start 5mlTO upCHILL to 4000ml ! requirements Label printing (ACL) ranging from AGI glaspac…..DelightingAGI glaspac: Largest customers since 1972 forehearth technology, we manufacturer of Beer bottle in single colour to six colour art work. Flint,PACKAGED Amber and Green glass can produce coloured glass containers suiting theAGI: brand glaspac Largest manufacturer of wine bottle AGI glaspac…..TO CHILL ! Delighting customersExperience purity since 1972 requirements in Green, Flint, Amber and coloured glass. in every sip ! ENABLING COLOURS….., ENABLING GLASS…. ExperiencePreserving purity authentic Olive Oil…, AGI: glaspac Largest manufacturer of wine bottle in every sip ! ENABLING COLOURS….., AGI glaspac: Leading manufacturer of in Green, Flint, Amber and coloured glass. ENABLINGAGI glaspac :GLASS…. Largest container glass

manufacturer of Beer bottle in AGI glaspac: Largest manufacturer of AGI glaspac: Leading manufacturer of glass jar AGI glaspac: Leading manufacturerFlint, Amber of range and Green of glass and bottes with product range 28ml to 4000ml soft drink bottles in Flint, Amber and Pharma and Chemical bottles capacity…, Various Shapes …,Neck Finishes.. PreservingGreen glass with authentic Applied Ceramic Olive Oil…, Our range start 5ml up to 4000ml Label printing (ACL) ranging from single colour to six colour art work.

AGI glaspac: LargestThrough colouring forehearth technology, we Through colouring PACKAGED manufacturer of Beercan producebottle coloured in glass forehearth technology, we PACKAGED Flint, Amber and Greencontainers glass suiting the brand can produce coloured glass TO CHILL ! requirements containers suiting the brand TO CHILL ! requirements

AGI: glaspac Largest manufacturer of wine bottleAGI: glaspacAGI glaspacLargest: Leading manufacturer of wine bottle in Green, Flint, Amber and coloured glass. in Green, Flint, Amber and coloured glass. manufacturer of container glass Preserving authentic Olive Oil…, Preserving authentic Olive Oil…, AGI glaspac: Largest manufacturer of AGI glaspac: Leading manufacturer of glass jar AGI glaspac: Largest AGI glaspac: Leading manufacturer of range of soft drink bottles in Flint, Amber and AGI glaspac: Largest manufacturer of Beer bottle in and bottes with product range 28ml to 4000ml Flint, Amber and Green glass Pharma and Chemical bottles capacity…, Various Shapes …,Neck Finishes.. Green glass with Applied Ceramic manufacturer of Beer bottle in Our range start 5ml up to 4000ml Label printing (ACL) ranging from Flint, Amber and Green glass AGI glaspac: Leadingsingle colour to six colour art work. manufacturer of container glass

AGI glaspac: Leading AGI glaspac: Largest manufacturer of manufacturerAGI glaspac of : Leading manufacturer of glass jar AGI glaspac: Leading manufacturer of range of containerand bottes glass with product range 28ml to 4000ml soft drink bottles in Flint, Amber and Pharma and Chemical bottles AGI glaspac: Largest manufacturer of Green glass with Applied Ceramic AGI glaspac: LeadingAGI glaspac manufacturer: Leading of glass jar capacity…, Various Shapes …,Neck Finishes.. AGI glaspac: Leading manufacturer of range ofOur rangeand start bottes 5ml with up productmanufacturer to 4000ml range of 28ml to 4000ml soft drink bottles in Flint, Amber and Label printing (ACL) ranging from Green glass with Applied Ceramic Pharma and Chemical bottles capacity…, Variouscontainer Shapes glass …,Neck Finishes.. Our range start 5ml up to 4000ml Label printing (ACL) ranging from single colour to six colour art work. single colour to six colour art work. AGI glaspac: Largest manufacturer of AGI glaspac: Leading manufacturer of glass jar AGI glaspac: Leading manufacturer of range of and bottes with product range 28ml to 4000ml Contact:soft drink bottles in Flint, Amber and Pharma and Chemical bottles capacity…, Various Shapes …,Neck Finishes.. Green glass with Applied Ceramic Our range start 5ml up to 4000ml HSIL Limited, PackagingLabel printing Products (ACL) ranging Division, from AGI glaspac, Glass Factory Road, Off Motinagar, P.B.No. 1930,single colour Sanathnagarto six colour art work. P.O., Hyderabad-500 018. Telangana, India. E-mail: [email protected] / [email protected] Phone: +91-040-2383 1771 Fax: (91)-040-2383 1787 Website: www.agi-glaspac.com www.aigmf.com Drawing Competition - Adopt a

Glass Bottle (June 5, 2018) Series of Events organized by Glass Industry ahead of World Environment Day

• 1st Prize (` 5,000) was given to Triman Dua aged 7 years, 2nd class student of Lancers Convent School, Prashant Vihar, Delhi. • 2nd Prize (` 2,000) was given to Riddhima Gupta aged 10 years, 5th class student of Delhi Public School, Rohini, Delhi. • 3rd Prize (` 1,000) was given to Rahul Kumar Kamat aged 13 years, 9th class student of Govt. Co-Ed Secondary School, Sector 15G Rohini, Delhi.

To commemorate World Environment Day, The All India Glass Manufacturers Federation (AIGMF) with the help of Education Department, Govt. of NCT of Delhi invited online entries from children between 7-16 years to participate in “Drawing Competition” on the theme “Adopt a Glass Bottle”. 1st Prize

Kanch | Vol. 6 | No. 1 | April-June 2018 7 Former Presidents, Mr. Sanjay Somany and Mr. S C Bansal were jury members who adjudged top 3 drawings out of 2000+ entries received from all over India. The formal award ceremony was held on June 11 at Hindustan National Glass Ltd. (HNG) Bahadurgarh plant where school children and invited guests were welcomed by Chairman of HNG, Mr. Sanjay Somany.

Mr. Somany said, “The 2nd Prize younger generation’s talent and perception Department of Govt. of NCT of not have been possible to encourage have been put on canvas with Delhi and Educational Institutions students to come forward to exemplary imagination using a riot of as without their support this would showcase their talent. colour”. As a token of appreciation, Winners along with their Office Bearers of the parents/teachers were Glass Federation thought taken for a brief tour it fit to give all participants of glass manufacturing a glass water bottle facility, which was (specially manufactured followed by award giving by Hindustan National ceremony. Glass and Industries Ltd.) with World Environment Mr. Bansal said, “With Day and Swachh Bharat overwhelming response Abhiyaan (clean India of 2000+ entries, campaign) logos  it clearly shows the enthusiasm amongst youth and making it tough to select top 3 Do you entries”. have news The program concluded to share? with Press interaction and lunch. Send your The All India Glass news and press Manufacturers releases to Federation (AIGMF) [email protected] acknowledged rd support of Education 3 Prize

8 Kanch | Vol. 6 | No. 1 | April-June 2018

July - September 2018 - Special Issue will carry detailed coverage of AIGMF supported Events, AIGMF Executive Committee and Annual General Meetings, 1st Glass Awards. The issue will be distributed at glasspro India 2018, World of Fenestration, CII’s Indian Green Building Congress and glasstec 2018 at Dusseldorf, GERMANY. To book advertisement space, mail to [email protected] by Sept15, 2018.

is the leading choice for advertising AIGMF website. in the glass and related industries. With A complimentary copy of KANCH along several years of publishing experience, with the invoice will be sent to all advertisers. unrivalled coverage for the worldwide glass Those wanting more than one copy are manufacturing community with up-to-date requested to send their request in advance. news, editorial and features, as well as For convenience, payment can also be exhibitions; KANCH is the best medium to remitted through wire transfer. Our bank communicate with stakeholders. details are as under: We understand your needs as an industry and are committed to assist you in making Remittance from Abroad to: your advertising most profitable. This also popularises your brand and product Bank of Baroda, New York, SWIFT BIC: BARBUS33, FEDWIRE/ROUTING Advertise in portfolio by establishing contacts to suit your company’s requirements. NUMBER: 026 005 322, giving full particulars of Beneficiary i.e. Good quality advertisement material along Account No. : 05860400000062 with a Cheque of the requisite amount Name : The All India Glass payable to ‘The All India Glass Manufacturers’ Manufacturers’ Federation Federation’ may be sent to Secretary AIGMF Bank : Bank of Baroda at the registered office of the Federation. Branch : Parliament Street It would be ideal if you could send your City : New Delhi, India advertisement in PDF high resolution format Payment Instruction Message i.e. MT - (with auto enabled e-mail ID/website address, 103 is to be sent to Bank of Baroda, IBB, if any) helping readers to reach you directly New Delhi, SWIFT BIC - BARBINBBPAR on a single click in KANCH’s e-version / Remittance from India to: Advertisement Tariff* (Deposit Cheque or make NEFT- online Indian Foreign payment) Companies Companies (US$) Account No. : 0411156983 Name : The All India Glass Ordinary Full page 15000 900 Manufacturers’ Federation Extra Inside Cover Page 18000 1000 Bank : Kotak Mahindra Bank

Inside Cover Page 20000 1100 Branch : G-39, Connaught Circus New Delhi Back Cover Page 40000 1800 IFSC Code : KKBK 0000214 Extra Folded Cover 40000 1800 (front) Page

Centerspread (two pages) 40000 1800 A copy of bank advice may please be sent at Half Page 10000 600 [email protected] for reconciliation 

The print area is 21.5 x 30.5 cm for full page advertisement.

GST as applicable. *subject to revision

10 Kanch | Vol. 6 | No. 1 | April-March 2018 www.aigmf.com Soda Ash for Glass Manufacturing (May 26, 2018) Series of Events organized by Glass Industry ahead of World Environment Day

The Executive Committee of The All response from students who have Natural Soda Ash, its place in the India Glass Manufacturers' Federation shared wonderful drawings and ideas Global Soda Ash Industry, New (AIGMF) met on May 26 at Hotel on adopting glass bottles in our daily environmentally focused demand Pride Plaza, Aerocity, Delhi. lives”. sectors e.g. lithium carbonate, The session started with welcome Parallel to Ex Com meeting, solar panels. address by Acting President, Mr. Raj a special session on Soda A glass bottle (specially manufactured Kumar Mittal who said, “we have Ash for Glass Manufacturing by Hindustan National Glass

been gifting glass bottles in all AIGMF was organised wherein Ms. and Industries Ltd.) with World events ever since Prime Minister Modi Marguerite Morrin, Executive Environment Day and Swachh Bharat announced Swachh Bharat Abhiyaan Director Chemicals, IHS Markit, Abhiyaan logos was launched enabling (clean India campaign)”. The bottles London was invited as guest people demand responsible and safe carry logo of Swachh Bharat Abhiyaan speaker who gave presentations packaging. showcasing Industry’s commitment on Global Overview on Soda A short video was released in Hindi for Green Environment. Ash and the Environment. Ms. on 'Benefits of Glass Packaging'. This Morrin said that Soda Ash is used Mr. Bharat Somany, Vice President video is in addition to English version in Glass Manufacturing, which is said that worldwide people are asking released in early 2018. for a ban on plastic, whereas we are produced both naturally as well giving one of the best solution’s on how as in chemical form. Ms. Morrin, AIGMF also released an update on to beat the pollution i.e. by adopting covered following main topics in Life Cycle Assessment (LCA) study a glass bottle. Mr. Somany said, “for her presentation, Top Producers, of “Container Glass” in India. This our most recent initiative on drawing Global Supply Profile, Capacity update was done for its earlier study competition for school children, Changes by Type & by Geography, released in 2012, which provides the we have received an overwhelming Soda Ash & the Environment, foundation for meaningful use of LCA

Kanch | Vol. 6 | No. 1 | April-June 2018 11 MASTERYS UPS Smart design for infi nite possibilities

results and to portray green image of the product amongst consumers and other stakeholders. purity. He further added that Glass is of glass containers for packaging Mr. Mittal said that Glass is 100% the trusted and proven packaging for drug formulations, food products or recyclable and can be recycled health, taste and the environment. Mr. beverages, which is directly linked to endlessly without loss in quality or Mittal assured uninterrupted supply Swachh Bharat Abhiyaan 

   new

We are the manufacturer of Neutral Tubes for Pharmaceutical Ampoules, Vials and Lab ware. We have Neutral Borosilicate (Type - 1) Glass Tube manufacturing plant with 3ind 01 1101 PUB the production capacity of 12 tons per day for sale, which includes Batch house equipments end fired double pass regenerative furnace with fore hearth, When intuitive design, intelligence and elegance muffles and two complete tube draw lines with its machineries and collide to create infinite possibilities accessories. • Exclusive “E-Wire” mobile app, an intuitive tutorial We are located in the state of Maharashtra (District Raigad), India. for a simplified installation • Integrated technology ready for the digital transformation • Superior certified reliability until 160 kVA Prospective buyers please contact us on following numbers and E-Mail ID: • Tailor-made - as standard MASTERYS GP4 - MASTERYS BC+ [email protected] 4th generation digital native UPS + 91 9004166665 [email protected] from 60 to 160 kVA + 91 9820156581 [email protected]

12 Kanch | Vol. 6 | No. 1 | April-June 2018 www.socomec.co.in/masterys-range

pub_1101013ind_masterys range.indd 1 16/01/18 15:48 www.aigmf.com

MASTERYS UPS Smart design for infi nite possibilities

new PUB 1101 01 3ind 01 1101 PUB

When intuitive design, intelligence and elegance collide to create infinite possibilities

• Exclusive “E-Wire” mobile app, an intuitive tutorial for a simplified installation • Integrated technology ready for the digital transformation • Superior certified reliability until 160 kVA • Tailor-made - as standard

MASTERYS GP4 - MASTERYS BC+ 4th generation digital native UPS from 60 to 160 kVA

Kanch | Vol. 6 | No. 1 | April-June 2018 13 www.socomec.co.in/masterys-range

pub_1101013ind_masterys range.indd 1 16/01/18 15:48 GLASS News

12th EXECUTIVE TRAINING CPWD and Mr. Shashi Kant, Adviser, (vi) Acoustics in Buildings – Design PROGRAM BY CCPS AND IBC CCPS & Former Dy. Adviser, Planning & Installation i/c Current Trends (Mr. ON 'INTERNAL CLADDING Commission on dais. Sandeep Mittal, Anutone Acoustics SYSTEMS IN BUILDINGS' Ltd.) (vii) Glass Use – Safety against One of thrust areas of Confederation Inaugural, Academic and Valedictory Impact (Mr. Shashi Kant, Adviser, of Construction Products and Services sessions was attended and participated CCPS & Former Dy. Adviser, Planning (CCPS) is to undertake training by 59 dignitaries which included 35 Commission). Participation Certificate alongwith all the presentations in CD form were given to all the participants for future reference and share with colleagues in their departments. Mr. Shashi Kant briefed about the scenario of spectacular rise of glass use in buildings and need for appropriate and safe use, development of “Guidelines on Safe Use of Glass in Buildings – Human Safety” by CCPS and its adoption by 25 States, Central and State Government Departments and PSUs. He also informed that the and skill up-gradation programs for senior officers as participants from recommendations of CCPS guidelines professionals on various subjects and Central PWD; MES, Siliguri; Air Force, were included in IS: 16231 (Part 4) topics. Recently two days Training Palam; PWD – Chennai, Madhya and revised National Building Code Program on “Internal Cladding Pradesh, Arunachal Pradesh, Haryana, of India 2016 (Part 4 FIRE AND Systems in Buildings” was organized Delhi; Chandigarh Administration; LIFE SAFETY Clause 3.4.10 Glazing by Indian Buildings Congress (IBC) DDA, IRCON, RITES and New Okhla and Part 6 STRUCTURAL DESIGN and CCPS on July 18 – 19, 2018 at Industrial Development Authority. Section 8 Glass and Glazing). IBC Head Quarters, New Delhi. This Topics covered during two days were was the 12th training programme (i) Need for Internal Claddings (Mr. FEVE ELECTS NEW VICE organized with IBC out of the total D.S. Sachdev, Former DG, CPWD) PRESIDENT 74 such programs done by CCPS. (ii) Internal Cladding Materials – Glass packaging body, the European The program was designed to update Green Options (Mr. Deependra Container Glass Federation (FEVE), engineers, architects and professionals Prasad, Green Building Consultant) has elected Mr. Michel Giannuzzi as particularly from Government sector (iii) False Flooring Systems (Mr. Rohit its Vice-President. about the requirements and latest Arya, Lindner Raised Floors System) The election of Mr. Giannuzzi, Chair- trends of internal cladding. (iv) Dry Walling and Partition The Program was inaugurated by Systems (Mr. Sachin Gupta, Saint- Mr. Abhai Sinha, President, Indian Gobain India Pvt. Ltd., Gyproc Buildings Congress & Former Business) (v) False Ceiling Systems Director General, CPWD with Mr. (Mr. Bhupender Kapur, Aerolite D. S. Sachdev, Director ITBP & Systems, Hyderabad) (vi) Bamboo Former DG, CPWD, Mr. P. S. Chadha, Flooring and Paneling (Mr. Sanjay Consultant IBC & Former ADG, Singh, Mutha Industries, Agartala)

14 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com man and CEO of glass packaging manufacturer Verallia Group, was announced during the FEVE annual general meeting held in Rotterdam on June 15. Mr. Giannuzzi, 53, was appointed to his position with the Verallia Group in 2017. Previously, he served as CEO of flooring surface company Tarkett between 2007 and 2017. He has also held positions with Michelin Group and Valeo Group. Mr. Giannuzzi commented on his consumers and other stakeholders. 1979 UP Twiga commissioned its new position, "I am eager to put first glasswool insulation line at this my experience at the service of U P TWIGA FIBERGLASS LTD., very site, bringing a new product ANNOUNCES ITS EXPANSION this industry which has an unrivaled and technology to India. In 2005, cultural heritage in Europe and a U P Twiga Fiberglass Limited UP Twiga entered into a partnership strong future ahead. Glass continues announced its capacity expansion with Isover Saint Gobain of France to be the packaging material of at one of the existing plant at to upgrade technology and product reference for many products despite Sikandrabad, UP by performing offerings, and in 2006 it commissioned competition.” ground-breaking ceremony on a new glasswool line of 12,000 tonnes "Our European industry association June 1. The guest of honour was Mr. in Ambernath, near Mumbai. Ranvir Prasad- Managing Director has a leadership role in federating With this ceremony UP Twiga starts UPSIDC, Mr. Ravi Mathur, Mr. Sushil forces towards a circular economy.” the process to increase its capacity Tripathi, Mr. Sanjay Somany and other by investing 100 crore rupees for UPDATE ON LIFE CYCLE distinguished guests. ASSESSMENT (LCA) STUDY OF this expansion. This new line will 'CONTAINER GLASS' IN INDIA Mr. Binoy Somaia, Managing Director increase company’s capacity to over welcomed a gathering on this land 24,000 tonnes per annum. At this On May 26, AIGMF released an up- mark occasion, ground-breaking scale UP Twiga will be one of the date on LCA study of 'Container Glass' ceremony of UPT’s new state of the largest, standalone manufacturer of in India. This update was done for its art insulation line. earlier study released in 2012, which glasswool insulation, or any insulation, provides the foundation for meaning- In 1976 a group of forward thinking in South East Asia for exploiting ful use of LCA results and to portray NRI entrepreneurs partnered with the phenomenal growth potential green image of the product amongst UPSIDC to start the company. In that India presents. UP Twiga and its partners will actively work on improving awareness of its products and their benefits to improve comfort level in houses and dwellings. Insulation stands for a better tomorrow. It is a known fact that children learn better, patients recover faster, and employee productivity improves in cooler and quieter environment. Company strives to take glasswool insulation in every corner of the country to make a difference in people’s lives. This new glasswool insulation line is a step in that direction.

Kanch | Vol. 6 | No. 1 | April-June 2018 15 izknsf'kd vokMZ ls uokts x, gSa] rkfd mudk eukscy Ck<+ lds vkSj of cooperation among European dkap uxjh ds pkj mn~;eh vPNh rjg mRiknu dj ldsaA fofnr gks and Indian counterparts that can be fd jkT; ljdkj n~okjk izknsf'kd iqjLdkj made. Let it be a document serving lqgkx uxjh dh pkj bdkb;ksa dh as expression of interest. There are o"kZ 2017&18 ds fy, mn~;ksx lsDVj esa >ksyh esa jkT; LRkjh; vokMZ vk x;kA a few areas, which can be worked. ftlesa uxj dk ,d izeq[k gksVy Hkh dkap uxjh dh rhu bdkb;ksa dk p;u The potential areas are: exchange and 'kkfey gSA 'kklu LRkj ij Pk;fur fd;k x;k FkkA blh izdkj flZol LksDVj training, sharing of non-technical and mn~;eh izknsf'kd iqjLdkj ls uokts x,A esa uxj ds izeq[k gksVy eksukdZ dk p;u good practice information, sharing 27 twu dks flfoy ykbal dkuiqj fLFkr fd;k x;k FkkA lekjksg esa lEekfur gq, of information regarding scientific epsZaV psEcj vkWiQ dkelZ lHkkxkj ij mn~;fe;ksa ds lkFk mik;qDr mn~;ksx 'kjn development taking place in academic mn~;e laxe lekjksg vk;ksftr fd;k VaMu Hkh ekStwn jgsA and research institutions etc. x;kA tgka dkap uxjh ds Pk;fur An important area that figured out PROF. DEVENDRA KUMAR mn~;fe;ksa dks jkT; LRkjh; vokMZ ls MEETS FEVE SECRETARY with a lot of scope and opportunities uoktk x;kA dk;ZØe esa ;wih ljdkj ds GENERAL TO EXPLORE is development of technologies lw{e&y?kq&Ekè;e mn~;ksx ea=kh lR;nso INDO-EU AVENUES IN GLASS and practices which can satisfy the ipkSjh us lekjksg eap ij mn~;fe;ksa dks SECTOR European or Indian regulations for reduction of CO , NOx and SOx lEeku fd;kA dk;ZØe esa mn~;ksx ea=kh Prof. Devendra Kumar, Member Edi- 2 emissions. In Europe there is one torial Board, KANCH and Head, De- us iwtk xzqi dh fgUn Xykl baMLVªht driving force for which is the BREF – a partment of Ceramic Engineering, IIT ls ;qok mn~;eh lfpu vxzoky] ekWMuZ document that lists the Best Available BHU VARANASI was in Belgium for Xykl baMLVªht ds lqjs'k panz caly] Technologies - agreed between the attending an International Confer- Vkbxj Xykl ls bdkbZ ds izfrfuf/ Industry and the Member States and ence. He also visited the Headquar- ,oa flZol LksDVj ls eksukdZ gksVy ds regulated under the EU’s Industrial ters of the European Container Glass lapkyd gjoa'k 'kekZ dks vokMZ iznku Emissions Directive. European Federation (FEVE) in Brussels on July fd;kA bl ekSds ij p;fur mn~;fe;ksa Commission is also going to table a 11th and had a meeting with Ms. Ade- legislation soon for the establishment dks 50 gtkj #i;s dk psd] 'khYM Ok line Farrelly, the Secretary General of of a new fund - an innovative fund for iz'kfLRk i=k iznku fd, x,A FEVE. In one and half hour long meet- decarbonisation and reduction of CO ing, discussions and information ex- 2 dk;ZØe esa mn~;ksx ea=kh ipkSjh us and other gases in power and energy change were done in many diversified mn~;fe;ksa dk mRlkg Ck<+k;kA mUgksaus intensive industries. The current EU subjects of the Glass World. Some dgk fd ljdkj izns'k ds vkSn~;ksfxd Research and Innovation Framework fodkl ds fy, yxkrkj iz;kl dj jgh points of the discussion which may Programme Horizon 2020 is open gSA blh Øe esa mn~;fe;ksa dks izksRlkfgr be of interest or points of focus were: to participation of entities from djus ds fy, vokMZ iznku fd, x, the environmental regulations in Eu- across the world in all parts of the ropean Union, programme, and many topics are new scientific flagged as being specifically relevant research in the for cooperation with partners outside area of the glass, Europe such as India. A new EU non-confidential research and innovation framework information ex- programme for the next decade is change and train- now under development and will ing of potential continue to be open to cooperation glass engineers. with Indian entities. The question is It figured that whether European and Indian glass there are many industries would like to utilise such constraints, but fund for innovative advancement the objective in glass sector with the help of the and approach Academic and research institutions. Mr. S C Bansal, Former President AIGMF and Owner Modern Glass Industries receiving award from Mr. Satya Dev Pachauri, is novel. This The meeting ended with a very Hon'ble Minister, MSME & Export Promotion, U.P. Govt. is a beginning positive note.

16 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com i;kZoj.k j{kk izfr;ksfxrk ds fotsrkvksa dks fd;k lEekfur vkWy bafM;k Xykl eSU;qiQSDpjlZ iQsMjs'ku }kjk i;kZoj.k j{kk dks ysdj vk;ksftr dh xbZ fp=kdyk izfr;ksfxrk ds fotsrk izfrHkkfx;ksa dks fganqLFkku us'kuy Xykl baMLVªht ds Ikfjlj esa iqjLd`Rk fd;k x;kA blls igys fotsrk fo|kfFkZ;ksa Ok muds lkFk vfHkHkkodksa] Ldwy ls tqM+s f'k{kdksa us Xykl iQSDVjh esa mRiknu izfØ;k ,oa i;kZoj.k j{kk dks ysdj mudh vksj ls viuk, x, rkSj&rjhdksa ds ckjs esa tkudkjh Hkh gkfly dhA i;kZoj.k j{kk ij gqbZ bl fp=kdyk izfr;ksfxrk esa Xykl cksry viukvks fo"k; j[kk x;k FkkA blesa cgknqjx<+] fnYyh ds vykok vU; Ldwyksa ls 2 gtkj izfrHkkfx;ksa us fgLlk ysrs gq, fp=kksa Ok muds lkFk i;kZoj.k dh vy[k as in business areas that include soda together with increasing welfare. txkus dk lans'k fn;k FkkA ,-vkbZ- and chromium compounds, Şişecam Having acquired the controlling stake th-,iQ- ds iwoZ vè;{k Jh ,l-lh- Group is strengthening its position and becoming the main shareholder of caly ,oa lat; lksekuh us fp=kdyk in the Indian market. The Group the HNGFL will enhance the Şişecam izfr;ksfxrk ds izFke rhu fotsrkvksa has acquired a further 49.8% stake Group's value creation potential. This transaction will significantly increase ftuesa igyk LFkku ikus okys 7 o"khZ; in its flat glass manufacturer affiliate, HNG Float Glass Limited (HNGFL). our flexibility to pursue strategic f=keu nqvk] nwljs LFkku ij jgys okyh initiatives and to benefit from the 10 o"khZ; Nk=kk fjf¼ek Ok rhljk LFkku Şişecam Group, which has been in a fifty-fifty partnership since 2013, now strong prospects offered by the Indian ikus okys 13 o"khZ; jkgqy dks udn market." iqjLdkj nsdj lEekfur fd;kA lat; owns 99.80% of the company shares lksekuh us i;kZoj.k dh vy[k txkus with this recent buyout. Emphasizing the production activities of Şişecam Group in 13 countries, ds fy, lekt ds lHkh oxksZa ls vkxs Stating that they are operating in Prof. Ahmet Kirman added that, four main business fields; namely "flat vkus dk vkàku fd;kA mUgksaus lHkh dks "Today, India is the fastest growing glass", "glassware", "glass packaging" jkstejkZ dh ftanxh eas Xykl ds iz;ksx automotive glass market in the world. and "chemicals", Şişecam Group's dks izksRlkgu nsus dh ckr dgh rkfd In terms of the interaction of the Vice President and CEO Prof. Ahmet vkus okyh ih<+h dks 'kq¼ okrkoj.k fey construction sector with the flat glass Kirman, said "In order to reach our ldsA fotsrk fo|kfFkZ;ksa us dgk fd market, it is considered that changes global strategic goals, we continue fo'o dh HkykbZ ds fy, gesa gj izdkj in user trends, as well as growth, will ds iznw"k.k dks fu;af=kr djuk pkfg, to seize high potential investment have a significant effect on the market. rkfd gkfudkjd inkFkksZa ds bLrseky ls opportunities in line with our In particular, with the popularity of gekjs thou ij gksus okys nq"izHkkoksa ij investment policy based on sustainable double glazing units, and an increasing jksd yxkbZ tk ldsA growth and high performance. The interest in insulated glass units, we buy-out we have just completed in estimate an annual increase of 7% ŞIŞECAM GROUP India is also a result of our long-term in architectural glass demand in the STRENGTHENS ITS POSITION and value-creating sustainable growth period of 2017-2023. Our production IN INDIA approach and our work in this scope. operations of flat glass and mirror are As one of world's leading India is one of the world's most continuing in India with a capacity of manufacturers in all main glass promising markets in terms of growth 600 tons/day at the HNGFL facility sectors, including flat glass, glassware, potential; it has considerable potential and we will continue our investments glass packaging, and glass fiber as well in terms of glass demand that is rising in line with the growth potential."

Kanch | Vol. 6 | No. 1 | April-June 2018 17 BOROSIL AND LISEC SIGNED CONTRACT FOR SECOND TEMPERING FURNACE At the trade show 'Intersolar' in Munich Mr. PK Kheruka (Vice Chairman Borosil), Mr. V Ra- maswami (Wholetime Direc- tor Borosil) and Mr. Christian Krenn (Sales Director LiSEC) signed a contract for a sec- ond tempering plant. Borosil has already been operating an AEROFLAT furnace from LiSEC since middle of 2017. The fast development of the SOLAR PV market and the increasing demand for solar glass encouraged Borosil to Mr. Christian Krenn (LiSEC) with Mr. V Ramaswami and Mr. PK Kheruka (Borosil) after signing make investment of INR 2.35 the contract (left to right) billion in expansion of its solar ŞIŞECAM GROUP ACQUIRES meters per year capacity. In 2016, facility including tem- SECOND FLAT GLASS Şişecam Group also acquired the pering. MANUFACTURING FACILITY Sangalli Porto Nogaro plant of Sangalli IN ITALY As a part of this project the second Group located in northern Italy. line has been ordered on LiSEC which Şişecam Group acquired the Sangal- is capable to give even higher output. liVetroManfredonia facility in Italy. SPECIALIST SUPPORT This represents the Group’s second FOR GLASS CONTAINER The tempering furnace Borosil flat glass plant in Italy. Trakya Cam PRODUCERS IN THAILAND commissioned is an AEROFLAT Sanayii A.Ş., a Şişecam Group com- Asia boasts some of the world’s most 12/714FT2 – this plant is designed pany, completed the acquisition of successful glass container production for tempering 2 mm thin glass. The SangalliVetroManfredonia plant in facilities, delivering a diverse range of specialty about this acquisition is Monte Sant'Angelo, Italy-based flat bottles and jars for beverages, foods, that LiSEC drives a development glass producer of Sangalli Group, for pharmaceuticals and other packaging project forward together with the $18.1 million. applications. Featuring advanced customer. The project’s aim is to “With this acquisition, our Group, manufacturing technologies, Thailand increase the output of glass elements Italy's largest Turkish investor, has in particular is home to some of the per hour. The new plant should be become one of Italy's largest flat glass region’s leading players. put in operation at Borosil in March producers and has strengthened its 2019. Mr. Christian Krenn about the leadership in Europe,” says Prof. In recent years, Heye International contract conclusion: “Borosil has Ahmet Kırman, Vice President and has realised significant sales growth once again opted for LiSEC. On the CEO, Şişecam Group. throughout this region, with key one hand they ensure that processes SangalliVetroManfredonia flat glass customers in the Philippines and are the same and they don’t have to production facility, located in the Vietnam, China, Korea, Taiwan as gain knowledge to operate a new southern part of Italy, has a capacity well as Thailand. The majority of plant. On the other hand, they rely of 190 thousand tons per year, along these installations feature Narrow on a supplier and partner who will with a laminating line with 4 million Neck Press and Blow (NNPB) accompany them long-term and square meters per year capacity, a forming process technology as an hence confirm that they are satisfied coating line with 4 million square alternative to conventional blow-blow with the so far delivered products and meters per year capacity, and a satin production methods. This advanced services” coating line with 1.5 million square equipment is assisting customers to

18 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com

The glass unit will to serve its existent customers in continue its operation the same way while now having under the new the additional back-up of Zippe’s company name Lahti specialists from its headquarters in Glass Technology. Wertheim, Germany. The previous owner “At the end, it is all about people,” has exited the glass said Mr. Günther Mlynar, MD of Zippe business. Existing Industrieanlagen. orders will however be completed with the “The enlarged engineering workforce support of the new and experience will perfectly entity. complement and strengthen Zippe’s own portfolio of highly-qualified Mr. Jarmo Näppi will specialists from which all customers be the new Managing will benefit at the end.” Director of Lahti Glass Technology and NEW TURKISH GLASSWORKS remains the contact BENEFITS FROM HEYE person for customers, PRODUCTION EXPERTISE Hot end and cold end training is now provided locally for along with his team of The latest greenfield glass container customers in Thailand by Heye International professionals. factory to enter production in Turkey increase production speeds and save Zippe CEO, Dr. calls on Heye International’s proven energy, while also improving returns Philipp Zippe, said: “We are extremely manufacturing expertise. Part of the on investment through the production happy about this acquisition, as it successful BastürklerSirketler Group of lighter containers. will create new opportunities in the of Companies, Bastürk Cam, a rela- An important feature of the development of new technologies, tively newcomer to the container comprehensive hot end and cold combined with the ability to serve glass industry, is located at the heart end products and services portfolio our customers even better through of the Malatya agricultural region of provided by Heye is the local increased service capabilities and an Eastern Anatolia. It is one of strongest availability of ongoing customer expanded geography for our national industrial establishments in the area support. In Thailand, for example, and international clients. and has been created to meet grow- Heye operates a training centre. A “Lahti will bring in further ing local glass packaging demand. training section has been installed to be competencies e.g. in the field of raw used for training purposes for the local The first phase of the recently com- material weighing, while we will also customer benefits. Two engineers are missioned glassworks features a 300 employed to provide detailed hot end collaborate in the field of Research tonnes/day glass melting furnace, and cold end training and support for & Development in order to create serving three Heye International Heye customers. Support is available outstanding technological solutions 12-section SpeedLine IS machines. 24 hours/day, seven days/week both for which the potential has now The machines are extremely flexible in Thai and English. It also includes become mutually bigger.” as they have been designed for 6 1/4 in double gob operations and 4 1/4 spare parts support and all remote “The technologies and individual in triple gob operations installation, services in particular, diagnostics, market strengths of both companies with short conversion times. Even a remote adjustments. complement perfectly,” said single gob production has been re- Mr. Näppi. ZIPPE ACQUIRES LAHTI’S alised. All three lines have been set GLASS BUSINESS Service-orientation will be up to make flint bottles and food jars. strengthened further due to an Batch plant specialist Zippe At the cold end, Heye International Industrieanlagen has acquired the increased international footprint and has co-operated with IRIS Inspection glass unit from the Finnish company a bundling of competencies. machines to deliver a combination of Lahti Precision. Lahti Glass Technology will continue HeyeSmartLine and IRIS Evolution 12

Kanch | Vol. 6 | No. 1 | April-June 2018 19 and Evolution 5 quality control equip- ment solutions. Already a major employer in the re- gion, the Bastürk glassworks brings valuable jobs to the town of Malatya, the 300 new recruits having been trained by Heye experts both locally and in Germany. “We have combined the best engi- neering and manufacturing features to meet our customers’ highest qual- ity needs” Bastürk Cam confirms. “Focusing on harmonising with in- ternational standards and continu- ous improvement in all of our activi- In 2019-20 we should see revenues to its European customers. ties, the glassworks project aims to coming in. In India, the demand for Nearly all PV module manufacturers capture the success achieved by the solar glass is about 375-380 tonnes buy solar glass from Gujarat Borosil BastürklerSirketler Group elsewhere a day, of which we contribute about Ltd. It also has a significant customer around the world.” 105 tonnes a day. Thus, we meet base abroad, mainly in the European 30 per cent of the Indian demand. Union. GUJARAT BOROSIL TO INVEST With the expansion, we will be able INR 2.35 BILLION IN SOLAR to cater about 60-70 per cent of the The company expects strong growth GLASS demand,” said Mr. Pradeep Kheruka, prospects in solar glass with the In- Vice Chairman, Borosil Glass Works. dian government’s strong impetus to The country's only Solar glass manu- solar power and encouraging policy facturer, Gujarat Borosil Ltd., plans to Gujarat Borosil Ltd., became the initiatives. invest around INR 2.35 billion to more world’s first producer of 2 mm tem- An Anti-Dumping Duty was levied last than double its manufacturing capac- pered solar glass in October last year. year on solar tempered glass imports ity by fiscal 2020 comprising facilities The most important feature of this from China. Currently investigation is for melting, forming and fully temper- glass is to efficiently manufacture in progress for similar duties against ing solar glass, which is invariably used glass/glass solar modules which will in the manufacture of photovoltaic allow the use of bi- glass modules. The company’s prod- facial cells, thus raising A glass bottle uct offering was recently enhanced the solar panel output (specially by 2 mm fully tempered solar glass. It by a whopping 25%. In manufactured by also now offers 2.5 mm and 2.8 mm addition, a well made Hindustan National fully tempered solar glass in addition glass/glass module of- Glass and Industries to its original offering of the industry fers an enhanced life Ltd.) with World of 40 years. The lower standard 3.2 and 4mm thicknesses. Environment Day thickness means the This is produced in its Bharuch facil- and Swachh Bharat sunlight has to pass ity, which has a capacity of 180 tonnes Abhiyaan (Clean through lesser sub- per day. With the investment, it plans India campaign) stance to reach the so- to increase this capacity to 400 tonnes logos was launched lar cell, thus boosting per day by 2020. The total capacity by AIGMF on May efficiency. This results shall stand enhanced to 2.2 Gigawatts 26, 2018 enabling in enhanced efficiency. of solar modules. people demand Gujarat Borosil has responsible and safe “The expansion for solar glass is al- started commercial packaging. ready underway. This should be over supplies of 2 mm glass by early part of next financial year.

20 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com imports from Malaysia. A safeguard Window and Door Manufacturers Winwall Technology, Dow India, duty of 25% has just been levied on Association (UWDMA). Schueco India and UWDMA. The imports of solar cells and modules. The workshop had theory sessions, participants visited three plants on This will greatly boost the production Case Studies, Demo Sessions and the second day to Saint Gobain India, of solar modules in India, and augurs Plant visits covering all aspects of the FUSO Glass and Sobha Glazing and well for the company since it serves Use of Glass and Glazing Systems in Metal Works. to expand its customer base. Buildings including Energy Efficiency, The workshop was well attended Safety, Structural Integrity and others by 44 Faculty members from 16 TRAIN THE TRAINERS as per NBC 2016. WORKSHOP ON USE OF Architectural and Engineering GLASS AND GLAZING The Workshop was addressed by academic institutions including SPA SYSTEMS IN BUILDINGS 15 eminent speakers from Industry Delhi, Sir JJ School of Architecture, and Academia including Mr. Arun As per National Building Code SAP Chennai, IIEST, Jadhavpur Kumar, Scientist E, Bureau of Indian (NBC) 2016 University, CSIR-CGCRI, Ramaiah Standards; Mr. Sharanjit Singh, Institute of Technology, Academy of Glazing Society of India (GSI), Indian Chairman, GSC Group; Mr. Mahesh Institute of Technology Madras and Arumugam, Director, Meinhardt Architecture and others. CSIR – Central Glass and Ceramic Façade Technology; Ms. Deepa The workshop was conducted as part Research Institute had successfully Sathiaram, Director, EN3; Mr. Antony of creating a group of trainers for conducted the first of its kind Train John, Technical Director, Schueco training the construction professionals the Trainers Workshop on Use of India; Ar. Deepak Gahlot, Director, on National Building Code 2016 Xebec Design; Mr. Ravishankar, Glass and Glazing Systems in Indian through a series of workshops at Technical Head, Dow Corning; Buildings as per National Building the respective academic institutions Mr. N Murali, Head – Design and Code 2016 at IIT Madras in Chennai participated in the event. from February 1-3, 2018. The three Sustainability, Saint Gobain India; day workshop was supported by Ar. Aditi Salway, Technica Expert, The event was concluded with a Bureau of Indian Standards (BIS), AIS; Mr. Sudhir Mohan, Technical formal vote of thanks from Mr. R Expert, Gujarat Guardian Ltd.; Mr. Federation of Safety Glass (FOSG), Subramanian, Chairman, GSI and Mr. Jothiramalingam, Director, Winwall The All India Glass Manufacturers' Sharanjit Singh. All the participants Technology and others. Federation (AIGMF), Confederation were awarded participation certificate of Construction Products and Services The event had three exclusive from IIT Madras and GSI  (CCPS), Glass Academy, International live demos by the Structural Glass (News Source: AIGMF Research Team/World Fenestration Forum (IFF) and uPVC Research and Testing (SGRT) Facility, Wide Web)

Kanch | Vol. 6 | No. 1 | April-June 2018 21 Programme(August17, AnnouncementThe 2018) All India Glass Manufacturers' Federation Interactive Session on Industry-related Risk and Opportunities AIGMF Glass Awards & Executive Committee / Annual General Meetings ------VENUE: Pride Plaza Hotel, Aerocity, Delhi Airport 1200 hrs Registration:Tea/Coffee 1210 hrs Welcome address by: Mr. Raj Kumar Mittal, Acting President, AIGMF Presentations on Industry-related Risk and Opportunities 1215 hrs Environment Law By Mr. Nawneet Vibhaw, Associate Partner, Khaitan & Co. 1230 hrs Competition Law By Mr. Manas Kr. Chaudhuri, Partner, Khaitan & Co. 1245 hrs Anti-Dumping/Indirect Tax By Mr. Kabir Bogra, Partner (Indirect Tax) Khaitan & Co. Q/A 1315 hrs AIGMF GLASS AWARDS CEREMONY

C K Somany Award (for Innovation and Technology) will be given to a recipient for valuable contribution in the field of technology/ manufacturing/innovation/services/education etc.

Balkrishna Gupta Award (for Exports) will be given to a recipient for valuable contribution in Glass exports. 1330 hrs Lunch 1430 hrs AIGMF Executive Committee Meeting (for AIGMF members only) 1515 hrs Annual General Meeting (for AIGMF members only)

PARTICIPATION: Free of charge - Non-members need to pre-register at [email protected]

List of Advertisers

AGI glaspac (An SBU of HSIL Ltd.) ���������������������������������� 6 Mascot Engineering Company. �������������������������� Back Cover

Empire Industries Ltd.- Vitrum Glass ���������������������������� 29 Nishal Group ���������������������������������������������������������������������1

glasstec 2018 ����������������������������������������������������������������� 9 Nipro PharmaPackaging India Pvt. Ltd...... glasspro India 2018 �������������������������������������������������������� 2 ...... Extra Folded Cover Gold Plus Glass Industry Ltd. ��������������������������������������� 30 R.D. Ashar Pvt. Ltd. ������������������������������������������������������...26 Gujarat Borosil Ltd...... 46 Socomec India Pvt. Ltd...... 13 Heye International...... 56 Twincity Glass �����������������������������������������������������������������12 Lubitech Enterprises ������������������������������������������������������ 40 Umda Enginering ���������������������������������������������������������....52 www.aigmf.com OPPORTUNITIES AND CHALLENGES POSED BY THE ENVIRONMENT FOR THE GLASS INDUSTRY IN INDIA

Mr. Nawneet Vibhaw is an Associate Partner at Khaitan & Co., New Delhi. He is a part of the firm’s Environmental Advisory and Dispute Resolution Practice. Mr. Vibhaw is an alumnus of NALSAR University of Law, Hyderabad and Lewis & Clark Law School, Portland, Oregon, USA. He is a member of the IUCN World Commission on Environmental Law and has received awards and fellowships from BELSPO, UKIERI, Robert Bosch Foundation, Asian Development Bank and MoEF&CC. Mr. Vibhaw has authored two books published by LexisNexis and chapters in international publications. The foreword to his book on Environmental Law has been written by Hon’ble Justice Swatanter Kumar, Former Chairperson, NGT and Former Judge of the Supreme Court of India. Mr. Vibhaw has also taught Environmental Law and Energy Law at National Law University Delhi and at Jindal Global Law School, Sonepat. He has contributed columns and articles in publications like The Hindu, Statesman, LiveMint, Business Standard, VCCircle, DNA, Mondaq and Lexology and has been a speaker at prestigious Nawneet Vibhaw environmental conferences in countries like USA, Australia, Germany, Spain, Philippines, Associate Partner, Khaitan & Co. [email protected] Belgium and India.

The recent World Environment Day India alone generates more than Management Rules 2016 (“Solid Waste celebrations, which India hosted, had 100000 metric tonnes of solid waste Rules”) provide for a framework ‘Beat Plastic Pollution’ as its theme. per day which is much more than what wherein the responsibility has been Since many states in India, including a few countries generate together. cast upon the glass manufacturers to Maharashtra have banned single-use While the per capita waste generation take the necessary steps to recycle and plastic, there is a great opportunity in India is considerably less than what manage the waste. Sorting of waste is for the glass industry to provide a safe we have in a few other countries, necessary for appropriate recycling and economically viable alternative cumulatively India generates a very and still remains a challenge in India. for it. With growing environmental large amount of waste which if not The Solid Waste Rules require the concerns the glass industry is only set managed properly would spin out of local authorities to set-up recovery to gain if it rises up to the challenge control. Glass is still a small fraction of facilities or secondary storage facilities to provide environmentally benign the municipal solid waste generated for sorting of recyclable material alternatives for sectors like packaging, in India. However, this share is set including glass from other types of construction, automotive and others. to grow substantially in future as the solid waste. The packaging industry alone is consumption of glass increases. It is Waste segregation is a major challenge expected to have a turnover of 32 here that the glass industry needs to in India and requires mass awareness, billion USD by 2020 in India. This adopt a proactive approach and work conscious efforts from relevant presents an excellent opportunity for together with the government and stakeholders and cooperation from the glass industry as glass is largely the regulatory authorities in various the consumers. This would help considered a safe packaging option. states to help manage the solid waste. facilitate a mechanism for the safe Waste management, be it solid, Therefore, while there are and efficient management of glass electronic, biomedical, hazardous, opportunities for the glass industry, waste. The Solid Waste Rules also construction or plastic, is steadily there are also a few challenges expect that the glass manufacturers becoming a serious issue in India. For especially the regulatory ones. From provide financial assistance to the a country with the world’s second an environmental perspective, one local authorities for the establishment largest population, it would be a such challenge is the management and of a waste management system. The daunting task to manage its waste. handling of waste. The Solid Waste glass manufacturers are also expected

Kanch | Vol. 6 | No. 1 | April-June 2018 23 to have a collection mechanism in place for collecting the packaging waste. It is important for the glass manufacturers to take appropriate initiatives to create awareness and educate the consumers for the safe disposal of the waste. This would help create a suitable mechanism for management of solid waste especially glass. Issues relating to the benefits of glass on health, hygiene, eco-friendliness and energy- efficiency have been raised before the courts as well. In Under Go-Green initiative, on World Enviornment Day, Secretary AIGMF, Mr. Vinit Kapur the case of Sanjeev Kumar v presented Glass bottles (with 'Swachh Bharat Abhiyaan'- Clean India campaign logo) to AIGMF State of Himachal Pradesh, a lawyers, Mr. Manas Kr. Chaudhuri, Partner (Competition Law) and Mr. Nawneet Vibhaw, case which dealt with the safe Associate Partner (Environment Law), Khaitan & Co (Right to Left). packaging of food and beverages It is important to note that or even tetra pack. Decarbonisation to ensure that it is safe for human environmental issues have now again, is both an opportunity as well as consumption, the Hon’ble High Court gained centre stage for businesses a challenge for the glass industry. Just of Himachal Pradesh passed a number like other industries glass industry will of directions, including one which in India. While we have always had great environmental laws, the also have to take appropriate steps to made the packaging of liquor and keep improving its efficiency. There soft drinks in glass bottles mandatory. implementation had traditionally been weak. However, with increasing is a need to constantly innovate, The Hon’ble High Court also held adapt and stay relevant to meet the incidents of environmental harm and that even for water it was better to demands of the ever-evolving market. the visible impact of environmental use sterile glass bottles as they would There is also a great need to create damage on human health, the prevent possible adulteration or awareness about the multiple benefits collective consciousness seems to contamination of the water. of glass-usage. have improved. It is this collective With sectors like food and beverages, consciousness and the awakened Glass industry still enjoys less than pharmaceutical, automotive, solar conscience that the glass industry ten percent of the market share in energy and real estate growing in needs to focus upon and use to its packaging. Therefore there is immense India, the glass industry seems to have advantage to promote and propagate potential for its growth from a a bright future. Besides packaging, in the benefits of using glass. That business perspective and acceptability the real estate sector, glass buildings glass is the most favoured material from an environmental perspective are being preferred as they are for packaging of pharmaceuticals if it manages to take the necessary built faster, are easier to maintain, and food and beverages, especially steps and precautions to adhere to improve energy efficiency and appear alcoholic beverages and that the the dynamic regulatory regime. The better aesthetically. The automotive alcoholic beverages market in India is old adage “One man’s loss is another sector too is experimenting with growing exponentially, will only help man’s gain” aptly suits the glass various kinds of glass, thus creating the glass manufacturers to increase manufacturers. What is being seen an opportunity for increased usage. as a loss to the plastic manufacturers their share in the packaging sector. With India set to generate 100 GW of due to the change in environmental solar power by 2022, the demand for Glass is seen as an environment- regulation in India, might as well be a solar glass is set to rise exponentially. friendly option for packaging. The gain for the glass manufacturers. The Increasing innovations by Indian glass companies seem to have spent glass industry needs to adapt and rise companies in the solar glass sector sufficient resources in devising forms to the challenges and the opportunity to make it environmentally safer and which are lighter, stronger and thus posed by adversity so that it grows much more efficient, will only ensure more environment-friendly. It is and gains substantially in the years to that the glass manufacturers gain from believed that the water footprint of come and contributes towards a safe the opportunity. glass is much less compared to plastic and healthy natural environment 

24 Kanch | Vol. 6 | No. 1 | April-June 2018 Opinion www.aigmf.com The glass industry waking up to its needs In his role as Principal Coordinator on the Advisory Board of Glass Futures, Dave Dalton addressed an international audience at the House of Lords in London this February about plans for twin Centres of Excellence for glass in the north of England, aimed at putting the UK at the forefront of global glass manufacture. Glass Worldwide (preferred international AIGMF journal) was there.

windfarms and factor in the container and push the boundaries. Glass Futures wants to work glass sector where we produce safe with everyone who will take the time to join with us on this material to store beverages and food journey to shape policy and integrate the idea of training and that lasts many times longer than developing people throughout their entire careers, keeping competitive packaging materials, the them fit for purpose and capable of passing their knowledge

CO2 and methane that is saved is to the next generation. This goes right through to training immense. Who would not want to people in R&D so that we can deliver world class results. support an industry that is actually Glass Futures has the support of a number of major making savings to the planet? universities and it is not just about the industrial aspect but academia too. As well as academia raising its concerns Two-part concept and what it needs in terms of solving problems backed Glass Futures is a two-part concept. by industry, industry should also be asking questions of We will have two centres, one with academia as to how their brainpower can be utilised to industrial-scale melting technology create solutions too. backed up by virtual reality and the The team from Leeds University is a staunch advocate other that will be more fundamental of Glass Futures and creating a centre around R&D that Dave Dalton addressed an international audience that included current BEIS ministers, senior civil research-based around university will lead us to not only evolving current materials but also servants and representatives of the Northern concepts. And within that, we have novel materials for the future. We are already researching Powerhouse, Innovate UK, Liverpool City Region, St Helens Metropolitan Borough Council, several the idea of a university hub to bring into fields such as photonics, medical devices, implants universities and leading suppliers. together collective capabilities in a and all manner of things that will revolutionise society in separate but very synergistic project to the future. How can we get that to be part of an integrated The glass industry has historically been ultimately share the same platform. glass industry that attracts global investment and interest? condemned as a polluter and despite At many levels, glass manufacturers By creating a common platform of R&D, training and being one of the smallest of eight such contribute immensely to society. But upscaling, such that we invite collaboration across the energy-intensive industries and with although their products are evolving sectors as well as from academia, industry, business and our ability to influence government on all the time, how can they reach their government to make sure that this investment works to punitive measures correspondingly potential without the right infrastructure maximum advantage and provides the best opportunity limited, we needed a way to increase and mindset? People need to be to develop the next generation to lead the world in glass our impact. Alongside other industries trained and developed to research technology. that have worked towards solutions to decarbonise, we produced a sector roadmap and as part of that process, Glass Futures was developed and is now close to becoming a reality, with two physical centres that will lead the way for the glass industry to demonstrate what can be achieved. Although we are castigated as an industry that pollutes, who would

imagine the entire amount of CO2 produced in glass manufacture across Britain and the EU is more than ten times mitigated by the products produced in the flat glass industry alone? We produce in the UK over a

million tonnes of CO2 but products we make such as efficient glazing systems and solar cells save ten times that

amount of CO2 in their lifetime. If you Dave Dalton alongside Lord Prior of Brampton, host of the House of Lords event (left), Richard Katz, a director of Glass Futures and Sir add to that the fibre that goes into Alan Langlands who represented the University of Leeds.

Originally published in Glass Worldwide, preferred international journal of AIGMF

GW77 May-June 2018 ALT.indd 38 10/07/2018 07:45 Kanch | Vol. 6 | No. 1 | April-June 2018 25 Opinion

Research experimentation Research at university and bench Siemens is leading us on this journey of introducing One of the difficulties in glass level does not demonstrate sufficiently technology, digitalisation and concepts like Industry 4.0. We manufacture research is the scale. what will happen if you make glass in aspire to be the first industry that completely digitalises its With large furnaces producing volume. Glass Futures will provide an process, employing data in real-time to rectify a problem hundreds of tonnes of glass every day opportunity at significant scale that will before it occurs… that is the future. With virtual reality, we can of the year with very tight margins, attract the industry to work with us to start to model things in a real sense to impact on what we there is no opportunity to conduct experiment. carry out with experimentation on the furnace that we build. research on a full-scale furnace without And around that, we will build Glass Futures is a Not for Profit Company, attracting impacting negatively on productivity. a world of virtual reality. Our partner interest globally in what we are aspiring to achieve. We are offering the hand of friendship across society to help get the glass industry in the UK to be at the vanguard of industry practice to reduce our energy consumption and carbon impact, demonstrating to other industries that this is an achievable target for industry in general. Let us embrace the challenges and collaborate to solve them. We all want a better future for the next generation and Glass Futures will provide a platform for a forward thinking and progressive industry to work together. This goes beyond normal economic boundaries… this is about the idea of an industry waking up to its needs. l

About the author: Dave Dalton is Principal Coordinator on the Advisory Board of Glass Futures and CEO of British Glass

Further information: Glass Futures Ltd, Chapeltown, Sheffield, UK tel: +44 114 290 1850 email: [email protected] Dave Dalton discussing Glass Futures, which will be the world’s first openly accessible, commercially available web: www.glass-futures.org and multi-disciplinary glass melting facility, with Chris Leonard, Director of Development at Ametek Land and Neil Simpson of Simpson Combustion and Energy Ltd.

7RPRUURZ·VWHFKQRORJ\² GHOLYHUHGWRGD\ 6ROXWLRQVIRU3URFHVV2(0V

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

VLHPHQVFRPSURFHVVRHP 95*6$

Originally published in Glass Worldwide, preferred international journal of AIGMF

GW77 May-June 2018 ALT.indd 40 10/07/2018 07:45 VRGS-A10007-00-7600 Anz_Process_OEM_A4.indd 1 31.07.17 13:07 26 Kanch | Vol. 6 | No. 1 | April-June 2018 Technology • Hot Sealing www.aigmf.com Hot sealing of aluminium films on glass containers Aluminium film hot sealing of containers is widely used to preserve different types of liquid and dry products. Even though the method is used mostly with plastic containers, glass packaging can be sealed in the same way, provided a proper coupling agent is applied on the glass finish. Originally published in Glass Worldwide (preferred international AIGMF journal), Dr Alberto Biavati comments on hot sealing specifications and requirements for food, perfumery and pharmacy airtight packaging.

Together with screw caps with or softened to stick to the container usually been neutralised by Na or Zn. Polymer carboxylic aluminium or rubber gaskets in brim surface during the hot sealing groups are responsible for the chemical bonds with glass or contact with the container brim, it process. Aluminium is an optimal coupling agent functional groups. is common to find screw caps that barrier against air, oxygen and Under the effect of temperature and pressure, ionomer after unscrewing leave an aluminium moisture penetration but its role is also carboxylic groups react with glass oxydrilic groups with film sealed on the container brim, to give to the film good mechanical water shift as a reaction product. Figure 2 shows that the that must be peeled off to open the resistance and to accumulate the container. Many containers are only thermal energy to seal the polymeric sealed by an aluminium film, without layer onto the container brim. an additional closure. This is the case, In the case of induction sealing for example, with yogurt pots etc. where there is no direct contact Aluminium films are sealed on between a hot sealing device and the container brim by hot sealing film, screw caps containing a gasket at temperatures in the range system made by a carton layer, a 100°C-150°C. This type of closure wax layer and the aluminium-polymer is actually widely used to preserve film are generally used. When the different types of liquid and dry aluminium layer is heated by a strong products to ensure the content against inductive electromagnetic field, wax

external contamination, to prevent melts and the aluminium-polymer film Figure 2: Simplified drawing of ionomer to glass direct sealing. the risk of air and oxygen penetration seals on the container brim under a and leakage, giving to the consumer constant pressure by the screwed cap. a good inviolability guarantee (figure1). At the cap, unscrewing the melted More often, plastic containers are wax lets the cap separate from the sealed in this way but glass containers aluminium-polymer film that remains can also be conveniently sealed in the sealed on the container brim (figure 1). same way. Aluminium mechanical resistance A hot sealing film is essentially is important to let the film peel from made from a thin layer of aluminium the container brim without tearing. By (~30-60µm), coextruded with a using polymeric layers of similar nature polymeric film thin layer that is melted of the plastic container, good sealing can be easily obtained. Figure 3: Simplified drawing of ionomer to organometallic coupling agent Due to the different nature of treated glass seal. glass from the film polymeric layer, the use of proper coupling agents is also necessary to obtain longlasting sealing performance with fatty and aqueous products. The polymer that can seal on glass is a proper ionomer ethylene-

Figure 1: Example of induction sealing with screw methacrylic acid or ethylene-acrylic closure and multi-layer gasket. acid, where the carboxylic groups have Figure 4: Simplified drawing of organometallic coupling agent treated glass.

Glass Worldwide is the This article is based on a paper presented at the XXXII ATIV Conference in Parma, Italy in official journal of ATIV November 2017. www.ativ.eu

Originally published in Glass Worldwide, preferred international journal of AIGMF

GW77 May-June 2018 ALT.indd 98 10/07/2018 07:44 Kanch | Vol. 6 | No. 1 | April-June 2018 27 Technology • Hot Sealing

so-formed chemical bond can be or others, potential direct contact shifted to the reactants due to the between the coupling agent and possible water penetration that can the product must be considered. A occur in the case of aqueous filling few coupling agents are suitable, products or environmental humidity. as they comply with ‘indirect food In other words, the direct ionomer- contact’ regulations but since inner glass bonds are reversible, with glass container dripping is sometime consequent film detachment due to probable during coupling agent

water or moisture penetration. To application, it is advisable that they Figure 5: Typical plot of ageing to peeling performance after coupling agent (CA) consider that the glass surface is comply with ‘direct food contact’ glass treatment. always hydrated due to its hydrophilic regulations. properties when exposed to air and Ageing stability of the treated glass performance generally observed over time. After coupling further subjected during storage to is quite important to guarantee good agent application, a slow trend of peeling force decreasing is weathering phenomena (hydrated sealing, even after months of storage. observed due to the ageing of the treatment (slow oxidation sodium carbonates formation after the To achieve good sealing performance, phenomena, glass sweating, occasional contamination etc). reaction between the sodium present the glass container brim must not be Such slow ageing trends are interrupted as soon as the on the glass surface and atmospheric contaminated and both coupling agent aluminium film is sealed on the glass brim, reasonably due

CO2 and moisture) that increase the chemical inertia and good storage to the stop to air exposure and environmental contamination degree of glass surface hydration. Film conditions are necessary. risk. Considering the example shown in figure 5, if the detachment usually occurs just after Usually, the following performance sealing had been at the sixth month instead of at the tenth tentative hot sealing. is required for the treated containers: month, an approximately parallel horizontal line starting Since water is the main • Before sealing (storehouse time): from 12 to 13 Nm should have been experienced. After the detachment agent, dry products have One year or more. sealing step, the peeling force follows a far slower trend of the main longlasting perspective. • After sealing (packaging life): Three performance decrease so that the peeling force can remain A few fatty products can indirectly years or more. almost unchanged over many years of ageing. promote the sealing weakening by Sealing quality control is made by peeling the film softening the ionomer layer. Glass brim surface manually or by a dynamometer after 10-15 hours of To reduce the glass surface general requirements immersion in water of the container filled with water. hydrophilic properties, a hot end The following requirements should be treatment of tin or titanium oxide is considered to optimise hot sealing: Conclusion conveniently applied on the finish • Hot end treatment to inhibit Aluminium ionomer films can be suitably hot sealed on glass but even if they give some benefit in glass sweating and increase the containers in the range 100°C-150°C, to guarantee the terms of hot sealing duration, they chemical bond strength between ageing of all air-sensitive products, foodstuffs, cosmetics alone cannot prevent film detachment coupling agent and glass. etc, by applying on the glass container brim a proper from glass in presence of aqueous • Clean glass finish surface, without coupling agent to guarantee the consumer against possible products. any contamination (fingerprints, packaging violation. So a coupling agent must be heavy cold end treatment, dust, Due to the different nature of glass and aluminium films, applied on glass in order to completely lubricants etc). coupling agents are necessary to guarantee longlasting inhibit the water detachment action • Even glass finish and parallelism sealing in the case of aqueous products to prevent water by establishing stronger, irreversible with container base to have a detachment action on the film sealing. Conventionally, a few chemical bonds between ionomer and regular pressure distribution. organometallic Zr, Cr, Al-based coupling agents or ethylene- glass (figure 3). • Glass finish flatness and thickness acrylic copolymer-based coupling agents are used. to increase the sealing surface. To obtain good sealing, a few requirements must be Coupling agents and glass hot satisfied: The correct choice of aluminium film and coupling sealing requirements Hot sealing performance agent, correct sealing parameters and glass container brim Two main categories of coupling agent Electromagnetic induction is usually cleanliness. The choice of coupling agent that complies with are available: the preferred sealing method but also direct food contact regulations is advisable. • Water solutions of organometallics direct heat conduction sealing has Generally, a performance of one year or more is (Al, Zr, Cr). good performance, provided an even demanded before sealing (storehouse time) and three years • Water dispersion of ethylene- and parallel glass finish is available. or more after sealing. acrylic copolymers. Peeling force should be Glass coupling agent treatment shows a slow trend of Thick layers of glues (not considered homogeneous in the range 4-12 ageing, with the consequent peeling force reducing. This in this presentation) are also sometime N/m. With higher peeling force, trend is interrupted as soon as an aluminium film is sealed used for hot sealing of unaqueous usually the film can tear and shreds on the glass brim, due to the interruption of air exposure so paste or dry foodstuffs in jars but since of ionomer remain on the container that the peeling force shows a completely different trend, they cannot be peeled off, they must finish. On one hand, this behaviour is often remaining almost unchanged for years. l be cut. a demonstration of good sealing and Very small amounts of coupling tightness of the closure but on the agent in the order of a few µg to less other hand, it is less appreciated by About the author: than one mg/cm2 are enough for the consumer for aesthetic reasons. Dr Alberto Biavati is a glass container technology sealing. The glass brim is heated in the Poor sealing homogeneity or weak consultant range 80°C-120°C and the coupling adhesion could be a symptom of Further information: agent is applied by a proper wet roller excessive treatment ageing, brim Dr Alberto Biavati, Italy (figure 4). contamination or wrong sealing tel: +39 0329 6515863 According to the nature of the conditions. email: [email protected] product, foodstuffs, drugs, cosmetics Figure 5 shows the sealing

Originally published in Glass Worldwide, preferred international journal of AIGMF

GW77 May-June 2018 ALT.indd 100 10/07/2018 07:44 28 Kanch | Vol. 6 | No. 1 | April-June 2018 29 Kanch | Vol. 5 | No. 4 | January-March 2018 See Your Happiness Through Gold Plus Glass

Gold Plus Glass Industry Limited

Apna Desh Apna Glass…

www.goldplusgroup.com | www.fb.com/goldplusglass | [email protected] www.aigmf.com SAFETY CONSIDERATIONS OF ARCHITECTURAL GLASS

Usha Batra Addl. Director General(Arch), CPWD, Delhi Mrs. Usha Batra is presently posted in Central PWD Head Quarters, Nirman Bhawan, New Delhi as Addl. Director General (Arch). She graduated in B. Arch. from Chandigarh College of Architecture in 1981 and Post Graduated in Public Policy and Sustainable Development from TERI University in 2014. She has been instrumental in designing many prestigious projects in CPWD. She authored, contributed and presented large number of technical papers on various subjects including energy efficiency, sustainability and glass.

Dr. K.M. Soni Chief Engineer, CPWD, Mumbai Dr. K.M. Soni is presently posted in Western Zone – I, CPWD, Mumbai. He graduated in Civil Engineering in 1980 and post graduated in Foundation Engineering from MANIT, Bhopal. He did his PhD in Geotechnical Engineering from IIT, Delhi in 1995 and MBA from IGNOU, Delhi. He has also done Certificate Course in Rural Environmental Management from University of Bangor, UK. He has been associated with large number of prestigious projects undertaken by CPWD. Dr. Soni has rich and wide experience of about 35 years in Civil Engineering Planning, Construction, and Maintenance. He authored, contributed and presented more than 125 technical papers on various topics and subjects at various forums.

Glass has become an essential backed polymeric safety and security and functional requirements. Optical, construction material for aesthetic films are also used on glass substrate solar, and thermal performance of and functional requirements in to modify breaking characteristics of glazing are required to conform to buildings being rare construction glass. material which is traditional, the characteristics such as spectral, multi functional and constantly Recently, a new section on “Glass thermal, light and UV transmittance, evolving. It is now widely used not and Glazing” has been added in the external and internal reflectance, only in windows and doors, but National Building Code (NBC) 2016 and solar direct transmittance. in partitions, railings, floorings, in which safety norms have largely Architectural glass includes annealed staircases, walls, and in special been included thus glass can now be glass, toughened glass, laminated architectural features. selected conforming to NBC for use glass, and heat strengthened glass. Though glass is highly brittle material in buildings. Toughened or laminated glass is but with certain modifications its Bird safety due to hitting the glass is still selected over annealed glass for brittleness gets altered as much as it an issue to be addressed particularly safety against accidental breakage and qualifies for being as fire resistant, heat in large windows and multi-storeyed strength requirements (mechanical resistant, impact resistant, and even buildings. Certain guidelines are also bullet resistant. Therefore, glass can needed to be included in the code for and thermal). Laminated glass is now be manufactured according to the bird safety. preferred for increased high security user requirements. Since all glasses do requirements, acoustic insulation, not possess same properties, it has to SELECTION OF GLASS sloped glazing and skylights. When be selected judiciously based on safety Architectural glass is selected based on there is any glazing within 1.5 m and other requirements. Adhesive aesthetic, functional or both aesthetic above the floor level of a building,

Kanch | Vol. 6 | No. 1 | April-June 2018 31 provisions given in NBC are to be also be followed to avoid injury due to human designed. impact. Certain locations like in and Additionally, around doors, low windows, door it has to be side panels, and panels mistaken for a ensured that doorway or openings are considered glass does more vulnerable than others for not break human impact. easily and When glass façade is used in the if broken, solar direction getting maximum heat it does not (normally south facing in India), effect cause severe of reflection has to be considered. injury due Death rays effect in London (Source: https://twitter.com/johnny_catsh) If concave façade is used, problem to falling on The design may include type of glass, is more likely to be aggravated on ground under normal as well as critical specifications, installation/fixing details opposite side of the building. In conditions like wind, earthquake or and performance characteristics such circumstances, sunrays hit the cyclone. of glazing assembly like breakage external glazed surface, get reflected Broken glass can also cause injury characteristics and structural due to concave surface, and focussed during handling and transportation integrity, giving full weightage to on small area on the ground or hence safety is also to be ensured safety requirements. In critical any other surface generating large during its handling, transportation, locations where there is likelihood amount of heat. An incident was storage and installation. Flat glass of injury due to breakage on account reported in London where a car should be transported vertically, and of wind, fire, earthquake, cyclone or melted due to heat from the reflected glass panes not allowed coming into any other condition, safety glass has sunrays (called death rays) from a 37 direct contact with each other by to be adopted. The installation is to storeyed office building. Also focal using appropriate interleaving layer of be carried out as per the provisions point will not remain same but as the powder, foam or paper. The lacquer given in the code else as per the sun moves, focal point will also move. opacified, enamel coated and screen manufacturer’s specifications in case Hence, this aspect is essentially to printed glasses are to be separated of provisions not available in the code. be considered during architectural by paper or foam. Clear/tinted flat planning and design while selecting The sites which are vulnerable glass, solar control/mirror coated the glass. Another factor is to be to unsafe environment like fire, glass and lacquered/painted glass are examined is wind effect when too blast, riot, theft, and vandalism, to be handled with dry, clean gloves, many skyscrapers are planned with special precautions are to be taken specifically after washing to prevent small gap between them. Even if wind and appropriate safety glass used stain marks on them, and care taken velocity is small at the entrance of accordingly. to avoid contact or friction with any such place from outside area, it may rough surface. suddenly increase in between the SAFETY GLASS space of skyscrapers due to Ventury The storage area at site should be Safety glass is a glazing material effect i.e. when a fluid passes through dry and well ventilated having almost treated or combined with other a constricted area its pressure reduces constant temperature. Glass panes materials to reduce the likelihood which in turn results into increase in are to be stored vertically on a soft of injury to persons by objects from the fluid velocity. Therefore, when surface such as wooden boards or exterior sources or by these glasses air passes through the small area battens. While stacking coated glass/ themselves when they crack or break between skyscrapers, wind velocity mirror in the unpacked condition, the in comparison with ordinary sheet, float may increase and accordingly the glass surface has to face towards the or plate glass. Though safety glasses buildings are to be designed. front i.e. paint/coated surface towards can break, their breaking patterns Thus, like concrete and steel are the back. reduce the injuries to a great extent. designed in a reinforced concrete Before installation, it has to be Such glasses have different breaking building based on loadings and other ensured first that the selected glass patterns as per their manufacturing critical conditions, glass/glazing should conforms to the design requirements. processes.

32 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com

To avoid broken glass falling on people from a height, threefold action required includes use of safety glass, removal of broken glass pieces immediately, and adopting architectural design in such a way that it follows safety standards given in the NBC. Safety glass may be toughened Breaking pattern of tempered glass Breaking pattern of laminated glass (Tempered) safety glass (TS) or laminated safety glass will generally not fall out of fixing. If Insulating Glass Unit (IGU) is glass (LS). Toughened (Tempered) However where laminated glass with installed in areas subjected to human safety glass is a single piece of specially both glasses toughened are used for impact on either side, both the panes heat treated with a stress pattern such horizontal or sloped glazing, in case of the unit shall meet the safety that the piece when fractured reduces of failure of both toughened glasses, requirements and in situations where to numerous granular fragments, with it may crumple as a blanket and fall access is restricted to one side of the no large edges. It breaks and out of fixing. Strength of the curtain unit, then only the accessible side should meet the requirements. disintegrates into small and relatively glazing system should be such that it harmless particles. However thick has the ability to hold glass in place and Safety glass is to be used in locations toughened glass particles may stay prevent it from falling out as a whole. where the risk of people getting hurt interlocked and fall as lumps of these Any broken glass in any glazing should by falling glass is high. Under some multiple particles and can cause a be removed immediately to avoid specific conditions, architectural minor or medium injury mainly due to particles to fall down and replaced design of the building and selection of glass is very important like in cyclone the weight of the cluster. with suitable safety glass only. prone areas. Though circular buildings In laminated safety glass, two or more Safety glass can be flat or curved are considered better in cyclone prone pieces of glass are held together by an and of any type which includes clear, areas, curtain glazing if provided, interleaving layer or layers of plastic tinted, coated, frosted, decorative the building has to be designed for materials. It will crack and break or mirror. TS glasses should satisfy wind forces and structural stability under sufficient impact, but the pieces the relevant resistance to shock test, of the entire system including roof of glass tend to adhere to the plastic fragmentation test and warp test and connectivity. and do not fly. If a hole is produced, LS shall comply with light stability test, FIRE SAFETY the edges are likely to be less jagged boil test and fracture and adhesion test than ordinary glass. Laminated safety in accordance with IS 2553 (Part 1). Due to rise in multi-storeyed centrally

Income Tax Building at Vejalpur, Gujarat Canara Bank Building, BKC, Mumbai

Kanch | Vol. 6 | No. 1 | April-June 2018 33 air conditioned buildings in India, fire glass is only one component of the also hit windows/glass by chance safety has become a major concern complete assembly hence glazing or even by seeing their own images particularly in buildings with curtain assembly must be fire resistant as in the glass and attacking on them. glazing as all the glasses are not fire such edge cover, gaskets and fixtures On colliding with glass, most of the also have equal role in fire safety. Fire birds die due to impact as shown in resistant. With required fire rated rated glass assembly must withstand the photos. (Source: https://video. glasses widely available, not only such the standard time during fire and give nationalgeographic.com/video/ glasses should be used but all fire adequate time to the occupants for news/141113-bird-window-crash- safety norms are to be followed such safe evacuation. Fire rated glass must vin and http://www.startribune.com/ as provision of adequate and specified also provide sufficient amount of vivid-photos-showing-bird-window- escape routes and refuge area, fire human impact safety even during fire. collisions/292994951/) detection and fire fighting (drenchers) To make windows safe from bird system, and use of required fire rating BIRD HITTING hitting, one has to examine the of glazing assembly. It has also to be Glass has the property of transparency, windows from bird’s point of view

Bird Hitting on Window ensured that during maintenance reflection and even translucence. from outside. It has to be observed period refuge area and terraces are These properties are used for whether vegetation, foliage, trees or not covered even with temporary advantage in buildings for humans but any other feeder source is visible on materials, and building use not altered for the birds, they sometimes prove glass which can attract birds and if so, without approval of fire authorities. to be catastrophic. It is estimated how glass can be made safe and bird Mock drills for fire safety provides that about one billion birds die from friendly. To deter the birds, vertical chance of replacing broken glasses window/glass hitting in US each and horizontal marking technique can if any. Fire resistance glasses include year. With multi-storeyed buildings, be applied on windows. It may be wired, annealed fire resistance, large glass panes being provided in in the form of strips, paint, stickers, windows, and green potted plants or tape on outside surface. Curtains tempered fire resistance, intumescent placed inside buildings, this problem also cut the visibility but they should laminated fire resistance, and double may increase in India also. At present, remain on the windows during glazed fire resistance glasses and there are no guidelines for preventing daytime and as such curtains of closely thus are to be selected based on site bird hitting in the codes. spaced ropes are also recommended requirements. Such glasses should As per the experts, bird hitting is of on interior side. Other arrangements be tested as they are not easily like screens, mosquito nets, solar distinguishable from normal type of two types called as day bird hitting and night bird hitting. During daylight, films also act as deterrent due to glasses. Normally, it is not the glass creation of partial opaque surface. but safety measures compromised birds crash into glass windows because they see reflection of vegetation or Commercially available options during planning or execution giving indoor potted plants/vegetation from to avoid bird hitting include ABC rise to the accidents. outside. As glass is transparent, they BirdTape, Acopian BirdSavers, Evonik It should also be understood that fire hit glass not anticipating hard surface. Soundstop Birdguard, bird safety resistance glass alone is not enough During night time, birds collide due films, Bedheim channel glass etc. to protect occupants from fire as to lighted windows. Sometimes birds In case, sunshades/chajjas are provided

34 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com

Commercially available options to avoid bird hitting over the windows, they also deter etc. Additionally, they modify the BIS has already brought out NBC the birds to collide. Basically, direct spectro-photometric properties of 2016 in which human safety has been path providing look of “no surface” the glass substrate and breakage included and must be followed while and greenery have to be avoided. In characteristics, and help in reduction selecting architectural glass. Safety Indian conditions, normally windows of heat and solar radiation. These guidelines to avoid bird hitting need were kept open during daytime in films are preferred at places where to be included in the code. old buildings and thus bird hitting solar radiation control combined was avoided automatically but with with safety and security features are REFERENCES new designs and concept of central required. 1. Draft Guidelines on Selection and Application of Adhesive Backed air-conditioning, windows remaining The security films pasted on glass for Polymeric Films in Glazing for closed during daytime, sunshades/ resistance to manual attack modify chajjas being avoided and potted plants Safety and Solar Control Purposes, the resistance against manual impact/ New Delhi. being placed inside rooms, bird hitting attack/forced entry and also delays may rise even though the problem may forced entry. They can be used on 2. Indian Standards IS: 2553 (Part 1)- not be that serious as in cold countries internal and external glass panes. 1990. Safety Glass - Specification, as curtains are used to block the heat The security films for resistance to Bureau of Indian Standards, New in India, particularly during summer. explosive pressure provide safety Delhi. against dangerous glass splinters 3. Indian Standards IS: 3548 – 1988. SAFETY AND SECURITY generated during explosion while Code of Practice for Glazing POLYMERIC FILMS ON GLASS security films for resistance to ballistic in Buildings, Bureau of Indian The purpose of applying adhesive attack during ballistic attack. Standards, New Delhi. backed polymeric safety films to a 4. National Building Code of India glass substrate is the modification CONCLUSIONS 2016, Vol. 1, Section 8 – Glass and of the breakage characteristics of Safety being of prime concern needs Glazing, Part 6 – Structural Design. the glass pane to which it is applied to be ensured during design, handling, Bureau of Indian Standards, New including additional benefits like transportation, installation and has to Delhi. reduction in heat and solar radiation, be considered for complete glazed and UV blocking etc. They are used 5. Soni, K M and Batra, Usha (2017). assembly during original construction Safety Considerations for Use at internal and external glass panes of as well as maintenance. Considering of Glass in Buildings, Seminar buildings where there is a possibility of wide variety of glass availability, on Health and Safety during injury from broken glass. These films appropriate glass needs to be chosen Construction, Indian Buildings provide safety against dangerous glass based on design and site specific Congress, Bhopal, 82-88. splinters which may be generated requirement. During maintenance, during glass breakage. 6. https://www.allaboutbirds.org/ safety glass should be replaced with why-birds-hit-windows-and-how- Security films to a glass substrate same type or superior specifications you-can-help-prevent-it/ provide resistance to manual attack, compared to the one installed during 7. https://abcbirds.org/get-involved/ explosive pressure, ballistic attack construction. Glass buildings require bird-smart-glass/ and resistance to attempted forced timely, adequate and specialised human penetration with tools such maintenance due to risk factor 8. https://info.glass.com/laminated- as hammers, screwdrivers, stones involved in them. vs-tempered-glass/ 

Kanch | Vol. 6 | No. 1 | April-June 2018 35 Float Glass Process and Applications – Revisited: Part I

Prof. (Dr.) A. K. Bandyopadhyay Technology Consultant & Ex-Principal Govt. College of Engg. & Ceramic Technology-GCECT, Kolkata [email protected] asisbanerjee.wordpress.com

Abstract

Float glass is a very important class of material and is of high commercial value. Its market is ever expanding that is going to take a gigantic proportion in the near future. It has not only a range of important applications but also the process is quite interesting by itself. The evolution of window glass or sheet glass into the present form of highly transparent and clear float glass is very interesting indeed in terms of historical perspective. All these aspects are discussed with a brief description of the float glass process in this Part-I of this article.

INTRODUCTION has a huge impact on the country’s not only directly in the glass industry Whenever we talk about glass, we Gross Domestic Product (GDP). i.e. making the basic products, but also mean transparent glass [1,2], i.e. a overall economy. Moreover, with the in the ancillary units making auxiliary glass that transmits light from the Sun increasing contribution of ‘automo- products for different market seg- to an enclosed area, i.e. to our build- tive’ industry in the overall economy ments. Moreover, there is a surge in ings (see Fig. 2 later). For a very long that stands at about 10% of our GDP demand for heat-protection. Hence, time, glass and building are almost at present, the usages for windscreen, both the present and future scenarios synonymous. In our building industry, window panes, driving panel boards, are quite lucrative. It also means that we cannot help but think about us- etc. also assume significance. Obvi- there is an increasing volume of prod- ing glass panels or sheets in windows ously there are other usages, such ucts, but the overall sales revenue in- and doors. Various other usages are as different types of panel boards for creases as well with the possibility of slowly evolving, such as staircase- electrical and electronics applications, value-addition in certain cases that is sides, small ‘connecting paths’ be- notably display boards for electrical a bonus for the glass manufacturers. tween two buildings or between two instruments, TV panels, Cell-phone Fire safety and environmental protec- portions of the same building, recep- and Tablet covers (i.e. flat-screen tion are some other important factors tion desks, security kiosk, separation products), etc. that also have to be satisfied by float panels within a large room to create The list can go on and on. In the not-so glass advocates [5]. smaller units, furniture fronts such as distant future, some more usages will Have we explained all the usages of cupboards, wardrobes or showcases, also evolve, particularly the latter type flat glass or sheet glass, collectively libraries, mirrors of all varieties and of usage, such as flat-screen glasses known as 'Float Glass'? No, not really, sizes – starting from the items in the that are worth billions of dollars in the as we have to talk about flat solar drawing room to bedroom to bath- world market [3,4]. In our country, panels [6]. In some countries, the rooms. with the advent of 'Make-in-India' consumption level of solar panels This is just a short list of items for and 'Skill-Development', this augurs made of ‘float’ glass can be as high building construction industry that well for the employment generation as 25-30% of the total consumption

36 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com of flat glass depending on their quest towards the growth of alternative by mouth was the technique available for alternative source of energy, source of energy via ‘float’ glass, i.e. in that period, and larger sheets of i.e. electrical power generation solar energy, which is also congenial glass were made by simply blowing via solar energy. After the ‘Paris and in line with various other efforts large 'cylinders' that were cut open Climate Accord’ in 2015, there is to reduce green house effect, and (2) and flattened, then cut into panes With the advent of the initiative of of various sizes. In the early part of creating ‘Smart-Cities' by Govt. of 19th century, most of the Window India in various parts of the country, glasses were made using this ‘cylinder the importance of solar energy for technique’. Such cylinders were 25 “pollution-free living environment” to 36 cm in diameter, and 180 to 240 cannot be belittled under any circum- cm long, that was a limiting factor for stances. Thus, the solar panels made determining the width of the panes of of ‘float’ glass truly serve two purpos- glass to be cut, and that also resulted es that are not only ‘trendy' but also in windows divided by wooden or 'useful' for fulfilling our energy needs. metallic frames into rectangular With the above background of ex- panels. Thus, making windows was plaining not-so-exhaustive list of ap- quite a tedious process in the early plications of ‘float’ glass, it is necessary days. to give a background on the historical In contrast, the modern windows are perspective of making sheet glass, made from float glass. Most float glass with a particular emphasis on ‘float’ is usually soda-lime-silica glass, with glass, whose transparency behaviour various additives. However, relatively is schematically shown in Fig. 2. smaller quantities of specialty ‘boro- silicate’ and ‘flat-panel display’ glass HISTORICAL PERSPECTIVE are also produced using the float glass As said earlier, plate glass, sheet process. Float glass is a sheet of glass glass or flat glass is collectively made by floating molten glass on a known as 'float' glass that has special bed of molten metal (typically tin), al- characteristics, such as high degree of though lead and various low melting transparency, uniformity of thickness, point alloys were used in the past. As high mechanical strength, and ease the molten tin has much higher den- of imparting various colours and sity than that of glass (4 to 5 times Fig. 1: Solar Paystation (Ref: Parking- Meter Hannover—20050625-111) various types of coatings to protect higher), the lighter glass floats on the our buildings from the undesirable metal making the surface very smooth wavelengths of Sun light, i.e. E-glass for optical clarity and better transpar- a competitive outlook for energy [7]. However, in the old days, ency. This method gives the sheet strategy, i.e. to reduce the burden this type of glass used to be called glass with uniform thickness and very of coal consumption that vitiates the 'Window Glass'. flat surfaces. The float glass process is atmosphere with undesirable smokes The story and fumes as well as increasing the starts at temperature of our earth. Apart about the 16th from energy, there are also other century, when usages and some of them are quite Window glass innovative, as shown in Fig. 1. or flat glass Here, there are two points to note: used to be (1) Although glass industry creates cut from large pollution by using coal or natural gas discs, called as fuel for melting in different types rondels, of of ‘glass tank furnaces’, that is signifi- crown glass. cantly compensated by contributing Air blowing Fig. 2: The Transparency behaviour of a Float Glass Piece

Kanch | Vol. 6 | No. 1 | April-June 2018 37 also known as the Process, erstaff of the UK's Pilkington Bros. “spout lip”. The amount of glass al- named after the British glass manufac- developed the first successful com- lowed to pour onto the molten tin is turer Pilkington Bros. that pioneered mercial application for forming a con- controlled by a gate called a ‘tweel’. the technique in the 1950s. tinuous ribbon of glass using a molten Tin is suitable for the float glass pro- Henry Bessemer, an English Engi- ‘tin bath’ on which the molten glass cess, as it has a high specific gravity, neer, who first made advances in flows unhindered under the influence it is cohesive and is immiscible with ‘automating’ glass manufacturing that of gravity. There was a need of care- molten glass. However, Tin oxidises were patented in 1848. His system ful balance of the volume of glass fed in a natural atmosphere to form tin produced a continuous ribbon of flat onto the bath, where it was flattened dioxide (SnO2) that is known in the glass by forming the ribbon between by its own weight. This was the key production process as ‘dross’. This a set of ‘rollers’. This was an expen- point of success of the float process. dross or, tin dioxide, adheres to the sive process, as the surfaces of the Full scale profitable sales of float glass glass. To prevent oxidation, the tin glass needed polishing before being were first achieved in 1960. bath is provided with a positive pres- used as window. It was thought that After giving a brief overview on the sure protective atmosphere of nitro- if the glass could be set on a perfectly evolution of the process of making gen and hydrogen. smooth body, it could considerably sheet glass over the long period of The glass flows onto the tin surface reduce the costs of production. Early time leading to float glass technique, forming a floating ribbon with perfect- attempts were made to form flat glass it is important to briefly mention the ly smooth surfaces on both sides and on a molten tin bath, notably in the manufacturing process. of even thickness. As the glass flows USA, and several patents were grant- along the tin bath, the temperature is ed, but this process was not work- MANUFACTURING PROCESS gradually reduced from 1100°C until able. Common glass-making raw-materials, at approximately 600°C, when the Before the float glass process was de- typically consisting of sand, soda ash, sheet can be lifted from the tin onto veloped, larger sheets of plate glass dolomite, limestone, and salt cake, rollers. The glass ribbon is pulled off were made by casting a large puddle etc are used for making float glass, the bath by rollers at a controlled of glass on a metallic iron surface, and except that their ‘purity’ is quite de- speed. Variation in the flow speed and then polishing both sides. This was a manding, particularly the iron content roller speed enables glass sheets of costly process. Hence, from the early to make clear glass with maximum varying thickness to be formed. Top 1920s, a continuous ribbon of sheet transparency. Other materials can rollers positioned above the molten glass was passed through a lengthy also be used as colourants, refining tin may be used to control both the series of inline grinders and polishers agents or to adjust the physical and thickness and the width of the glass thus reducing both glass losses and chemical properties of the glass. The ribbon. cost. This was again a part of the long raw-materials are mixed in a batch Once off the bath, the glass sheet period in the development process. process, then fed together with suit- passes through an ‘annealing lehr or Further, lower quality flat glass was able cullet (waste glass), in a con- kiln’ for approximately 100 m, where made by drawing a thin sheet upwards trolled ratio, into a furnace where it is it is cooled gradually so that it anneals from a pool of molten glass that was heated to approximately 1500°C. The without any ‘strain’ and does not crack held at the edges by a set of rollers. typical float glass furnaces are 45 m due to the change in temperature. On As the glass cooled, the rising glass- long, 9 m wide and contain more than exiting the "cold end" of the ‘annealing sheet stiffened, and then it could be 1200 tons of glass. Once molten, the kiln’, the glass is cut by computer- cut. The two surfaces were of lower temperature of the glass is stabilised controlled machines [8,9]. quality i.e. not as smooth or uniform to approximately 1200°C to ensure as those of float glass. This process a homogeneous specific gravity with THE MARKET continued in use for many years, even higher viscosity. Finally, a very brief overview of the after the development of float glass. The molten glass is fed into a "tin float glass market is given here. Pres- In the field of innovation in the float bath", a bath of molten tin (about 3–4 ently, the world float glass market, glass process, the final moments came m wide, 50 m long, 6 cm deep), from not including China and Russia, is between 1953 and 1957, when Sir a delivery canal and is poured into the mainly dominated by the four com- and Kenneth Bick- tin bath by a ceramic lip known as the panies: Asahi Glass (Japan) with about

38 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com

25% market share, Nippon Sheet to continuous improvement of the City and Glasses for Flat Screen Glass (NSG-Pilkington, Japan), Saint process technology with innovative Products – Part II”, Kanch, Vol. Gobain (France) and Guardian Indus- ideas and cost consideration. A brief 3[4], (2016), 21-24. tries (USA). Other companies include market view is given after the process 4. A. K. Bandyopadhyay, "Technology Sise Cam AS, PPG (USA), Central description that is elaborated further of Float Glasses", Kanch, Vol. 5[3], Glass, Hankuk (HanGlas), Zeledyne, in the Part-II of the article with a (2012), 33-36. and Cardinal Glass Industries. There comparison of the characteristics 5. A K Bandyopadhyay, “Glass Safety is a tremendous competition in the of one larger furnace with that of a for Building Construction and market not only to increase the mar- smaller one. There are still many new Environmental Protection – Part I”, ket share in the building construction ideas not only on the basic appearance Kanch, Vol. 2[5], (2015), 7-11. industry (i.e. the major consumer) but of float glass in terms of transparency 6. S. Das (University of North Texas, also in different fields of industrial ac- and clarity but also on various newer USA) and A K Bandyopadhyay, “A tivity, e.g. solar glass panels in the en- applications that could bring little Perspective of Renewable Energy ergy sector. More market segmenta- bit more profit to the glass industry. and Solar Photovoltaic Power Plants”, Kanch, Vol. 2[4], (2015), tion means more market penetration The future in terms of both tonnage 21-25. by a particular company depending on and sales value looks bright with the the strategic process involved [10]. increasing use of solar panels and the 7. A K Bandyopadhyay, “E-Glass as an development of ‘Smart-Cities’. Important Component in Building CONCLUSIONS Construction”, Kanch, Vol. 2[4], REFERENCES (2015), 11-16. As float glass is very important in 1. A. K. Bandyopadhyay, "Glass - A the glass business, it is important 8. A. K. Bandyopadhyay, “Nano Sustainable Building and Packaging Materials”, Tunbridge Wells, UK, to disseminate the knowledge on Material", published and printed (2010). float glass to the manufacturer as by Vinit Kapur on behalf of AIGMF, well as to the user industry. After New Delhi, (March, 2016). 9. J. Zarzycki, “Les Verres et l’Etat Vitreux”, Mason, Paris, (1982). an introduction with most of the 2. A. K. Bandyopadhyay, important applications covered, a "Transparency in Float Glasses and 10. A K Bandyopadhyay, “Strategic historical perspective is given as to some Applications", Kanch, Vol. Management in the Glass how ‘window glasses’ progressively 2[3], (2014), 23-26. Industries”, Kanch, Vol. 2[1], transformed into ‘float glass’ due 3. A. K. Bandyopadhyay, “Smart (2014), 9-12 

SOMANY CONFERENCE HALL at office

"Somany Conference Hall" can accommodate 18- 20 people.

Hall is equipped with 43" Smart Wi-Fi TV, Computer work station and other basic facilities.

AIGMF members can avail Hall for business meetings (at no charge) which could be planned between 10 am to 5 pm, Monday to Friday and 10 am to 2 pm on Saturdays.

Booking is however subject to its availability on a working day.

Request for booking may be sent at [email protected]

Kanch | Vol. 6 | No. 1 | April-June 2018 39

www.aigmf.com Life Cycle Analysis (LCA) of Container Glass in India – 2017

BACKGROUND OF THE predominant factors for consumers collected and analysed for container STUDY in India while selecting a packaging. glass. The data has been collected In 2011, AIGMF conducted 1st Though the developed nations have from member companies of AIGMF. LCA study of Container Glass in taken a number of steps to retain The representative upstream data India that was performed and glass packaging for the sake of (mainly raw materials, energies, reviewed against ISO 14040/44. environment & health, very little is fuels, and ancillary materials) were The study was carried out being done in India by the Govt. Thus, obtained from GaBi 8 database 2016 and are representative of the years by PE International AG using it becomes all the more important for 2016 onwards. Overall, the quality GaBi 5 Software for life cycle the glass industry in India to educate of the data used in this study was engineering. It was a Cradle- the consumers about goodness of considered high for glass. to-Cradle study which is the glass vis-à-vis other packaging. Glass Industry also has gone through ultimate test in assessing the KEY RESULTS OF THE STUDY environmental impact of a technological improvements in terms As evident, the values of most of the product because it ensures that of less emission, light weighting etc., during last 5 years or so. With this environmental impact indicators for all aspects of a product’s life, in mind, AIGMF decided once again 1 kg of container glass have reduced end-of-life and reincarnation to engage Thinkstep (erstwhile PE in 2017 as compared to that in are accounted for. The study International) for updation of LCA 2012. These reductions are due to showed that not only Indian results obtained in 2011 using the following reasons: glass manufacturing process is same software and to bring the same highly energy efficient & adopts • Reduction in electricity and under public domain. best in the world technologies fuel consumption - In the melting process, the specific but with increased recycling by PROCEDURE consumption of fuels like heavy 75% & reduced weight by 20%, The goal of the study was to fuel oil, liquefied petroleum gas environmental footprints of glass understand environmental impact and natural gas has reduced can further be reduced by 50%. of container glass - focusing on by 20.5%, 14.3% and 19.1% From 2011 – 2017, plastic/PET cradle-to-cradle assessment and respectively from 2012 to 2017. packaging penetrated significantly to identify and investigate potential Also, the specific electricity into glass bottle segments, be it improvement opportunities for consumption in melting process liquor, soft drinks, beverages or container glass packaging. In the study, has reduced from 2012 to 2017 by pharma. In spite of glass being most site-specific data representative of 29.0%. In non-melting process, environment friendly & hygienic, current technology used in India the specific consumption of cost & convenience became more of reference year 2016-17 were propane, diesel and natural gas

1. ENVIRONMENTAL IMPACTS FOR 1 KG OF CONTAINER GLASS IN 2012 AND 2017 LCA STUDY Impact Categories UOM 2012 Results 2017 Results % Improvement

Acidification kg SO2 eq. 0.0083 0.0056 33% Eutrophication kg Phosphate eq. 0.0006 0.0003 50%

Global Warming kg CO2 eq. 1.0900 0.5811 47% Human Toxicity kg DCB eq. 0.1900 0.0954 50% Photochemical Ozone kg Ethene eq. 0.0003 0.0002 33% Terrestrial Eco Toxicity kg DCB eq. 0.0026 0.0011 58% Primary Energy Demand MJ 13.600 7.7513 43%

Kanch | Vol. 6 | No. 1 | April-June 2018 41 has reduced by 16.4%, 17.8% impacts which 3. COMPARISON WITH OTHER PACKAGING and 16.6% respectively from would have MATERIALS: (TAKING GLASS RESULTS AS 2012 to 2017. The specific been due to BASE 100 IN 2012) electricity consumption in non- manufacturing Impact Glass - 2012 Glass - 2017 PET melting process reduced from new container Categories 2012 to 2017 by 6.0%. glasses. Acidification 100 67 60 • Increased recycling rate - The 2. COMPARISON Eutrophication 100 50 69 recycling rate of the container OF NORTH Global Warming 100 53 57 glass increased from 32% in AMERICA GLASS Human Toxicity 100 50 123 2012 to 45% in 2017. Increased INDUSTRY AND Photochemical 100 67 136 recycling rate of post-consumer AIGMF Ozone cullet resulted in substitution The chart represents Terrestrial Eco 100 42 246 of virgin batch materials. Toxicity Consequently, this indirectly the comparison of results for 1 kg of Primary energy 100 57 74 resulted in reduced energy demand consumption in the melting container glass of furnace as identified in the first North American glass as clearly the greenest & safest point above. Glass Industry, results of old study mode of packaging for human beings of AIGMF and results of new study & ecology as a whole. • Increased reuse rate - The rate of AIGMF. It shows that Indian glass For container glass industry of reuse of the container glass manufacturing process is highly increased from 30% in 2012 in India, energy efficiency, energy efficient & generates less weight reduction through to 35% in 2017. This increase carbon footprint compared to its resulted in reduction of production new technologies and a better American counterpart. recycled glass (cullet) collection, As evident from the table, in segregation & treatment process India today glass packaging has will help to reduce its footprints less environmental footprints further. It is equally important compared to PET/Plastic to create awareness about the packaging on almost all aspects positive impacts of glass packaging except acidification where through its entire life cycle and it is slightly higher. Hence, educate consumers on the same this result clearly establishes as well 

Vol. 6 | No. 1 | April - June 2018 Quarterly Journal of Glass Industry, published and printed by Vinit Kapur on behalf of The All India Glass Manufacturers’ Federation from 812, New Delhi House, 27 Barakhamba Road, New Delhi – 110001 and printed at New United Process, A-26, Ph-II, Naraina Industrial Area, New Delhi-110028

Quarterly Journal of The All India Glass Manufacturers’ Federation T:+91 11 2331 6507 F:+91 11 2335 0357 E: [email protected] Bi-lingual

Special Feature Member Editorial Board:

• Drawing Competition - Adopt a A K BANDYOPADHYAY Glass Bottle • Soda Ash for Glass Manufacturing Former Principal, Govt. College of Engineering & Ceramic Technology-GCECT, Kolkata • Opportunities and Challenges posed by the Environment for the Glass Industry in India DEVENDRA KUMAR • The Glass Industry Waking up to its Needs • Hot Sealing of Aluminium Films Prof. & HOD, Dept. of Ceramic, Indian Institute of Technology (Banaras Hindu University) on Glass Containers • Safety Considerations of Architectural Glass K K SHARMA • Float Glass Process and Applications – Revisited: Part I President, NIGMA and Plant Head, HNG Neemrana, Rajasthan • Life Cycle Analysis (LCA) of Container Glass in India – 2017 • Cold End Project between the Editor: MOHAN LALVANI Ganges and Yamuna Rivers • Indian Pharmaceutical Plants serve the World Complimentary copy for Members / Government Departments / NGO's and those connected • Float Glass Process Technology – Revisited: Part II with Glass Industry • Raising our Glasses to the Glass Industry Free online version at: www.aigmf.com/kanch.php Upcoming Events - Aug 17 (Details on page # 22) • Interactive Session on Industry- Charges for Print issue: related Risk and Opportunities • Ist AIGMF Glass Awards Indian Companies: ` 125 per copy • Annual General & Executive Committee Meetings Annual Subscription ` 450 1st Prize (winning entry) of Drawing Competition on ‘Adopt a Glass Bottle’ held on World Enviornment Day - June 5, 2018 Foreign Companies: US$ 25 per copy Annual Subscription US$ 80

42 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com Technology • Ware Handling Cold end project between the Ganges and Yamuna rivers India’s Gold Plus Glass Industry Ltd is now operating two float glass production lines that feature Grenzebach cold ends. Jan Lukassek discussed the latest project in Glass Worldwide, (preferred international AIGMF journal).

A 380,000m2 float glass production Glass at the Grenzebach Group. It is facility is great for a big celebration the second time that Grenzebach has and this was proven by the managers, delivered the cold end for a float line to employees, business partners and Gold Plus Glass Industry. guests of the Gold Plus Glass Industry About four weeks after the Ltd. The company’s latest float line heating-up ceremony in Roorkee, recently went into operation at the located about 180km north of Delhi, Roorkee plant, which is situated the first glass floated on the tin bath of between the Ganges and Yamuna the production line and was conveyed

rivers with festive ceremonies. by Grenzebach conveyors. The facility With a length of approximately 190m, the cold end equipment from Grenzebach The furnace of this 700 tons float produces 700 tons of float glass every is the end of the latest float glass production line at Gold Glass. Shown here is line was heated up in the presence day on a 24/7 basis. the main line course towards the continuous ribbon area. of several hundred spectators in an Grenzebach solutions for the extensive firing-up ceremony by opening processing and handling of flat glass Defective glass plates are removed onto an inclined line the gas tap. The ceremony was started with thicknesses of 2mm up to 12mm section with integrated conveyor belt and are removed by a religious act based on Hindu beliefs. is a perfect fit for the permanent into the crusher. Glass qualities are sorted onto double-deck The heating up ceremony was followed 24/7/365 manufacture of float glass. conveyors with a piano function. by a tour through the production halls. “Highest cutting and stacking accuracy, Safe unstacking of the glass comes at the end. There Finally, a copious meal was served a best possible defect rate and highest are three sidelegs with stackers and rotary platforms, where to all guests. “It was one of the most availability of the equipment are decisive glass sheets can be handled in single and double mode. sumptuous feasts in which I ever criteria of success for use in float glass Especially for big formats and inhomogeneous glass sizes, participated during a factory opening” production” says Mr S S R Murthy, there is a separate jumbo stacker. said Jan Lukassek, Sales Manager Plant Head of Gold Plus Glass Industry. “We will support the cold end in close co-operation with “Grenzebach is a reliable as well as the experts from Gold Plus over the complete life cycle” an innovative partner for a stable says Jan Lukassek. “That the management already relies on production process.” Grenzebach technology for the second production line is real confirmation that our service for the equipment is already on and jumbo stackers the highest possible level.” More than 300 Grenzebach lines The Grenzebach cold end line is are currently used in the glass industry worldwide. equipped with a thickness and strain measuring system, emergency Important player in India cross cutter and a scanner for glass “By means of the new line, we are able to extend our sheet inspection. Quality control is capacity from 470 tons to 1170 tons of float glass/day” supported by means of automated Jimmy Tyagi, Gold Plus Glass Industry Director explains. “We Combined cutting along with a marking bridge, have extended our product palette to all sorts of tinted and where defects are automatically tinted reflective glasses. Furthermore, we are able to extend Art made from glass: Jan Lukassek (right), Sales marked. It goes without saying that an the existing clear glass series.” Manager Glass at Grenzebach, presents a glass automatic production process control Gold Plus Glass Industry Ltd is a major player in the sculpture to Subhash Tyagi, Chairman at Gold Plus Glass Industry Ltd. is integrated as well. Indian flat glass industry. The company, which sets the focus glass expertise on today’s produc-tion, processing and trading of various glass categories, was founded in 1985. It was the first Indian-owned company involved in float glass production. l

About the author: Jan Lukassek is Sales Manager Glass at Grenzebach Maschinenbau Contact us for more info Integrated glass process solutions

Further information: A CNUD-EFCO International NV/SA Grenzebach Maschinenbau GmbH, Asbach- Noorderlaan 30, B-1731 Zellik, Belgium & extended services Bäumenheim, Hamlar, Germany T +32 2 481 88 00 tel: +49 906 982 2000 E [email protected] Leading annealing lehr & float bath provider email: [email protected] W www.cnudefco.com web: www.grenzebach.com Improve your production yield and energy efficiency with us! From the main line, three sidelines lead towards stackers, rotary platforms and jumbo stacker at the line end.

Originally published in Glass Worldwide, preferred international journal of AIGMF

GW77 May-June 2018 ALT.indd 108 10/07/2018 07:44 Kanch | Vol. 6 | No. 1 | April-June 2018 43 Factory Spotlight There’s only Indian pharmaceutical ONE WAY plants serve the world to make an high quality product Gerresheimer’s new plant in Kosamba, India has received ISO 15378 certification for the production of vials and ampoules, while a new furnace at the group’s PAS-12 and PAS-9 Neutral Glass factory will make type I glass. the new Amig jug forming machines

Gerresheimer owns two plants at its Kosamba site in India: Bottles, vials and ampoules made from tubular glass for India. Neutral Glass and the recently completed Gerresheimer Pharmaceutical Packaging Mumbai factory to make vials and ampoules from tubular glass. Neutral Glass manufactures moulded glass products for the pharmaceutical industry. The plant will soon receive a high performance furnace to make type I glass.

ISO 15378 certification “Our new plant in Kosamba produces ampoules and vials made from borosilicate glass to the same high standards as apply in Europe or the Americas” says Saibal Sengupta, Sales Director. “All of our production and inspection processes are standardised and certified worldwide. In February, we received ISO 15378 certification.” The plant is already certified in accordance with the following standards: ISO 9001:2015, US DMF Type III and Health Canada (DMF). Phase I for certification in accordance with the ISO standard 15378 has been completed. The final audit was carried out by the end of January, meaning that the plant’s certification runs from February. ISO 15378 applies to primary packaging that comes into direct contact with medication. The standard covers all materials commonly used to make primary packaging such as glass, rubber, aluminium and plastic. ISO 15378 gives all GMP standard and gain international pharmaceutical products benefit from contract manufacturers and all manufacturers that package acceptance at an early stage. the fact that the standard incorporates such materials themselves an opportunity to secure a high Suppliers of primary packaging for all the relevant GMP requirements and facilitates compliance with international, European and national law.

Glass vials Vials are among the world’s most popular pharmaceutical packaging solutions and Gerresheimer produces versions in clear and amber glass that can hold between 1ml and 50ml. The range of tubular glass vials on offer in Asia includes clear and amber glass types I and II. All manner of different shapes are available, either with or without blowback and compliant with either international standards or the customer’s own specifications. PAS-12

Ampoules PAS-9 The company also offers a wide range of high quality pharmaceutical ampoules made from pharmaceutical glass type I. The standard portfolio includes ampoules made from clear and amber glass that can hold A diverse portfolio of glass pharmaceutical bottles is offered. between 1ml and 30ml. Among these

Originally published in Glass Worldwide, preferred international journal of AIGMF

Amig_Pas-12_Pas-9_adv_V03.indd 1 2/18/2014 8:50:31 PM GW76 Mar-Apr 2018.indd 24 26/05/2018 20:26 44 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com Factory Spotlight

products are straight stem, funnel-type and closed ampoules that comply with GPS, the future the relevant ISO standards (types B, C and D) with various break systems such as OPC (one point cut), CBR (colour break ring) and score ring. Customer-specific requirements can also be implemented alongside the is clear customary ISO standards.

Camera inspection systems Gx Rhoc, the camera inspection system developed by Gerresheimer, ensures exceptional dimensional quality for vials. Several HD cameras detect every flaw.

Furnace rebuild “Constructing a new furnace for type I glass will significantly enhance our quality” says Sachin Sule, Head of Sales and Marketing for moulded glass. In India, for example, Vials and ampoules made from tubular glass are produced at the new Kosamba facility. Gerresheimer manufactures clear and amber glass infusion and injection of medications. The production line at Gerresheimer’s complete range encompasses all bottles from type I borosilicate glass. this factory is certified in accordance classes of glass used for pharmaceuticals – types II and III The company also produces type III with DMF (Drug Master File) type III sodium silicate, as well as type I borosilicate. This enables glass containers for a large number requirements. the company to supply the perfect glass packaging to suit drugs of any shape or size. Its extensive glass range means that appropriate packaging solutions can be found for even the most sensitive pharmaceuticals.

Bottles and vials made from A diverse portfolio of glass pharmaceutical bottles is moulded glass for India. offered, extending from the smallest glass cartridges made from tubular glass up to large acid-resistant chemicals bottles. Gerresheimer employs cutting edge techniques and monitoring technology from the development stage right through to production and packing for delivery. With bases in the Americas, Asia and Europe, the company specialises in manufacturing primary packaging for pharmaceuticals in line with the relevant pharmacopeia. All of its factories are currently certified to standards including ISO 9001. l

The Neutral Glass plant for the production of moulded glass in Kosamba. Glasproduktions-Service GmbH Ruhrglasstraße 50

Further information: 45329 Essen, Germany Gerresheimer Pharmaceutical Packaging Mumbai Pvt Phone +49 201 36 00 771 Ltd/Neutral Glass & Allied Inds Pvt Ltd, Mumbai, India tel: +91 22 2926 2323 Fax +49 201 36 00 737 email: [email protected] [email protected] web: www.gerresheimer.com Gerresheimer’s new plant in Kosamba, India has received ISO 15378 certification for the production of vials and ampoules.

Originally published in Glass Worldwide, preferred international journal of AIGMF www.gps-essen.com

GW76 Mar-Apr 2018.indd 26 Kanch | Vol. 6 | No. 1 | April-June 201826/05/2018 45 20:26

www.aigmf.com Float Glass Process Technology – Revisited: Part II

Prof. (Dr.) A. K. Bandyopadhyay Technology Consultant & Ex-Principal Govt. College of Engg. & Ceramic Technology-GCECT, Kolkata [email protected] asisbanerjee.wordpress.com

Abstract

As an important class of material, “float” glass stands apart. It has also high commercial value, making this segment of glass business very attractive. With increasing activity in the real estate sector, its market is expanding to blow up to a greater dimension in the not-so distant future. It has not only a range of important applications but also the process is quite interesting by itself. The evolution of window glass or sheet glass into the present form of highly transparent and clear float glass is explained as historical perspective in Part-I of the article. Although a brief description on process technology for making ‘float’ glass was given earlier, the details are explained in the Part-II of the article with a comparison of a larger glass tank furnace with that of a smaller one. This gives rise to a better insight into this interesting process technology.

INTRODUCTION or for automotive glass along with cut lites or from broken cut lites, is blended with the mixed batch to make Among all the plate or sheet glasses, hundreds of other glass fabrications. up from 15% to 30% of each batch; the “float glass” made by floating a Float glass manufacturing is not like generally, it is 25%. The mixture is sheet of glass over molten tin bath the manufacturing of commodities like then delivered to the melting furnace is the most popular, and it is also steel or plastic. Each of the processes by a belt conveyor. a technologically involved subject requires raw materials to be weighed, of concern to the glass industry in mixed, melted at high temperatures, The batch house consists of silos, general, and the building construction formed into continuous ribbons, hoppers, conveyors, chutes, dust industry in particular. The novelty of cooled and cut into a size that fits collectors, and the necessary controls to properly handle the raw materials this process is that the accuracy of its use. Float glass is made from a combination of several ingredients and mixed batch. The raw materials the glass thickness free of any surface such as sand, soda ash, dolomite, storage and handling is designed to aberrations or irregularities are limestone, salt cake, and cullet with suit the types of glass which will be exceptional, which is inherent in the lowest iron content. produced along with the availability process technology itself. The raw materials are received and and cost of the raw materials. Float glass offers the quality of stocked in the silos or in the optional The mixed batch is delivered from the plate glass combined with the storage areas. If the raw materials are batch house to the furnace storage lower production cost traditionally stocked in the optional storage areas bin, by a belt conveyor system, associated with sheet glass they are then moved as needed to where it is stored and then fed into manufacturing. Float glass is virtually the silos. The raw materials are then the furnace at a controlled rate by distortion and defect free, making drawn down from the silos for batch the batch charger. As the batch is it ideal for various premium glazing weighing and mixing. Cullet, which is fed into the furnace melter area, it applications in buildings and homes crushed glass from edge trim of the is heated by the natural gas burners

Kanch | Vol. 6 | No. 1 | April-June 2018 47 to approximately 1593C. From gradually reduced allowing the glass cutting area by a system of rollers and the melter, the molten glass flows to become flat and parallel. drives linked to the lehr drive system. through the refiner then through the The glass is scored by carbide cutting The “float furnace” consists of sup- ‘waist’ area, where platinum stirrers wheels, parallel and perpendicular to port steel, upper and lower welded homogenize the glass, then into the ribbon travel, into sizes that meet steel casings, a refractory liner, tin, the working end where the glass is electric heating elements, an oxygen the customer requirements of the allowed to cool slowly to the proper eliminating atmosphere system, tem- plant. The scored glass ribbon is then temperature for delivery to the float perature sensors, and a computerized separated into lites for packaging by furnace, i.e. tin bath. process control system. Each float ‘unloading personnel’ or automatic The melting furnace consists of furnace is specifically designed to re- equipment for transfer to the ware- refractory bricks and special shapes, spond to the following: (a) heat flow room for storage or shipment to the support and binding steel, insulation, balance, (b) desired ribbon width, (c) customer. The cutting system consists a fossil fuel firing system, temperature glass thickness, (d) glass colour, and of steel support frames, a mechani- sensors and a computerized process (e) the gross daily production ton- cal roll drive system, "X "and "Y "cut- control system. The design of the nage. ting system, a glass trim and scoring furnace is carefully made to meet system, manual unloading conveyors The glass leaves the float furnace the plant's specific gross daily glass and/or semi-automatic or automatic at about 593C and enters the production tonnage goals. The unload systems and a computerized annealing lehr, which controls the insulation, special airflow features, process control system. and combustion air heating enable the cooling of the glass. The glass ribbon THE COMPARISON furnace to operate at maximum fuel is carried through the lehr by a efficiency with negligible emissions of series of rollers driven by motors Having explained the process in some pollutants. The furnace is sized and and a (controlled) mechanical drive details, let us now do a comparison designed to provide high quality glass system. The temperature of the glass of various characteristics between with the smallest amount of energy is reduced according to a precise a large furnace of 1600 tons per day per ton of glass melted. time/temperature gradient profile, (TPD) and a smaller furnace of 650 established for each annealing lehr, to TPD that is common in India. Both From the working end of the melting produce glass that meets the “industry furnaces are side regenerative type furnace, the glass flows through standards”. The time/temperature with natural gas and furnace oil as fu- the canal area and then into the profile, for all of the glass thicknesses els, and they have electrical boosting float furnace (tin bath or float bath) and colours produced by the plant, to maintain a proper temperature. onto molten tin. The float furnace is installed in the computerized atmosphere is controlled by a mixture The melting temperatures are 1593C annealing lehr process control system. of 94% nitrogen and 6% hydrogen and 1580C. A lower temperature of gas to prevent the tin from oxidizing The components of the annealing lehr melting results in a lower exit tem- to form tin dioxide or “dross” that include a steel lined inner chamber perature of 1050C compared to that is harmful to the smooth surfaces of and a steel outer shell separated by in- in the larger furnace at 1093C. The float glass. sulation, steel alloy and insulated steel larger furnace has an area: 53.1 mt rollers, a mechanical drive system, air The molten glass, which by now has × 9.1 mt, i.e. 483 sq. mt and with a circulation fans and ducts, heating ele- dropped to 1093C, forms a continu- glass level 1.22 m, the volume of glass ments, and temperature sensors and ous ribbon that floats on the molten will be 590 cubic mt that gives rise to computerized process control sys- tin. The desired width and thick- a total weight of glass as 1300 tons tem. The design of the annealing lehr ness is obtained through an opera- that is lower than the design capacity is adapted to meet the critical “cool- tor controlled program, which sets of 1600 tons. Hence to achieve this ing down” requirements of each float the speed of the annealing lehr and production target (specified by the plant's gross daily production tonnage knurl machines. The ribbon thickness design), the glass level has to be 1.5 and glass colours. can range from 2 to 12 mm. As the mt that is hardly possible, but it could continuous ribbon moves through The cooled glass ribbon exits the an- be sometimes raised to 1.4 mt, as the the float furnace, its temperature is nealing lehr and is conveyed to the market demand is high at times.

48 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com

For the smaller furnace, the area is tin bath 'exit' temperature is also quite criteria ultimately makes it more 33.6 mt x 8.5 mt, i.e. an area of melt- high at 688C, i.e. a drop in tempera- expensive, as tin is quite expensive. ing at 290 sq mt and with a glass level ture of 350C over a smaller length of It should be mentioned that the tin inside the tank furnace at 1.05 mt, the only 48 mt that gives rise to 7.3C/mt bath atmosphere is 94% nitrogen and volume of glass will be approximate of tin bath. In contrast, the 'exit' tem- 6% hydrogen in both cases – to avoid 305 cubic mt. This is equivalent to perature of tin bath for the smaller the oxidation of tin to tin dioxide that 670 tons of glass, whereas the design furnace is only 650C, i.e. a drop of is not good for the 'surface finish' of capacity is 650 tons. Here, the data 355C which is remarkably similar – the float glass. For the larger furnace, typically indicate a tank furnace for as it has to be considered in terms as the temperature of glass is quite float glass that exists in India and the of viscosity increase or rather fluidity hotter, the number of 'Rolls' needed glass level of 1.05 mt seems to be ad- drop – that should be the 'same' for is only 6, whereas for the smaller equate, although here also there is a technological purpose. However, for furnace it is 7 – the reason is quite chance of increasing the glass level at the smaller furnace, this drop of 355C obvious. The 'Roll-to-Roll' distance least to 1.2-1.3 mt for getting 10-20% is over a larger length of tin bath of 58 is also maintained at 1.5 mt in both more production when the market mt, i.e. a drop of 6.1C/mt of tin bath, cases demand peaks. which is slower and involves a less Finally, the annealing of the float glass risky design, but the tin bath length Let us now move from the tank fur- after it comes out of the tin bath cannot be changed without a major nace to the tin bath, where the pro- needs to be compared. The anneal- disruption in production. duction action actually shapes up. The ing 'Lehr Entrance' temperature for “entrance” temperature to the tin The width of the tin bath is always both cases is 610C, whereas the 'Lehr bath for the larger furnace is 1038C, higher at the 'entrance' or front side, Exit' temperature is also quite simi- as the tank furnace exit temperature whereas it is tapered to a smaller width lar at 282C and 285C respectively. is quite high at 1093C, i.e. a drop of at the back end, i.e. the 'exit' end. The This gives rise to smooth removal of temperature of 55C between fur- front/back width of the larger furnace 'stress' from the hot glass. Although nace and tin bath that is congenial for is 6.1 mt/4.3 mt, whereas that for the the 'lehr entrance and exit' tempera- an adequate increase of viscosity or smaller furnace is 6.0 mt /4.2 mt, i.e. tures are quite similar, the lehr length rather decrease of fluidity of glass rib- quite similar. The depth of tin for the is 116 mt and 110 mt respectively that bon to a level so that it can straighten former is 5.1-7.6 cm, whereas that gives rise to a slight advantage on the out to a great 'flatness'. On the other for the smaller furnace is 5.5-7.5 cm. removal of 'stress' from the float glass hand, the 'entrance' temperature to All these data combined and for the former case. the tin bath for the smaller furnace is considering the difference in length at 1005C, i.e. a difference of 45C, i.e. CONCLUSIONS of tin bath in both cases ultimately 10C less than that of the larger fur- require smaller volume of molten The technology of float glass process nace. This may have a small effect on tin at 150 cubic mt for the larger has been revisited in the Part-II of the viscosity thereby on the 'flatness' furnace compared to that in the this article, where many details have of the glass. smaller furnace at 165 cubic mt, i.e. been given step by step in order to Obviously, for the larger furnace, the 10% more. So, a change in design have a full insight into the process

https://www.facebook.com/AIGMFIndia/ https://twitter.com/AIGMF_

Kanch | Vol. 6 | No. 1 | April-June 2018 49 technology. It is clear that it is a very guide the future investment into the "Transparency in Float Glasses and involved process and quite compli- field, as the demand for such glasses some Applications", Kanch, Vol. cated in terms of precise control of increases with the advent of 'Smart- 2[3], (2014), 23-26. viscosity-temperature relation of a Cities'. 3. A. K. Bandyopadhyay, “Smart float glass chemical composition that City and Glasses for Flat Screen is multi-component in nature. The REFERENCES Products – Part II”, Kanch, Vol. 3[4], (2016), 21-24. comparison has also been made of a 1. A. K. Bandyopadhyay, "Glass - A larger capacity (1600 tons) furnace Sustainable Building and Packaging 4. A. K. Bandyopadhyay, "Technology with a smaller one (650 tons) that Material", published and printed of Float Glasses", Kanch, Vol. 5[3], (2012), 33-36. also gives insight into how the design by Vinit Kapur on behalf of AIGMF, of such process is made vis-à-vis pro- New Delhi, (March, 2016). 5. J. Zarzycki, “Les Verres et l’Etat cess control operations. This will also 2. A. K. Bandyopadhyay, Vitreux”, Mason, Paris, (1982) 

Membership of the Federation

Members of the Federation are classified into two categories; manufacturers of primary glass articles are enrolled as Ordinary Members of the Federation and suppliers to glass industry viz., suppliers of machinery, raw materials, consultants and others connected with glass industry are enrolled as Affiliate Members. Foreign Companies supplying machinery etc., to glass industry are also enrolled as Affiliate Members. Membership forms can be downloaded from www.aigmf.com/membership.php Members of the Federation are enrolled on the recommendation of Zonal Associations viz.: yy Eastern India Glass Manufacturers' Association (EIGMA) yy Northern India Glass Manufacturers' Association (NIGMA) yy South India Glass Manufacturers' Association (SIGMA) yy Uttar Pradesh Glass Manufacturers' Syndicate (UPGMS) yy Western India Glass Manufacturers' Association (WIGMA)

ADMISSION FEE / ANNUAL SUBSCRIPTION Ordinary Members: -- Admission fee ` 5000/- -- Annual subscription: Single Unit: ` 27,500 + GST as applicable -- More than one Unit: ` 1,10,000 + GST as applicable Affiliate Members: -- Admission fee ` 5000/- -- Annual subscription: ` 11,000 + GST as applicable -- Applicants for enrollment for a period of five years may pay a consolidated amount of ` 49,500 (including admission fee) + GST as applicable Affiliate Members from countries other than India: -- Admission fee US $ 200 -- Annual subscription: US $ 440 + GST as applicable -- Applicants for enrollment for a period of five years may pay a consolidated amount of US $ 1650 (including admission fee) + GST as applicable ■

50 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com

About

The All India Glass Manufacturers’ Federation

The All India Glass Manufacturers' Federation was founded in 1944. The Federation is made up of five Regional Associations viz. Eastern India Glass Manufacturers' Association (EIGMA)-Kolkata Northern India Glass Manufacturers' Association (NIGMA)-Haryana South India Glass Manufacturers' Association (SIGMA)-Hyderabad Uttar Pradesh Glass Manufacturers' Syndicate (UPGMS)-Firozabad and Western India Glass Manufacturers' Association (WIGMA)-Mumbai The Federation was incorporated under the Companies Act, 1956 (No. 1 of 1956) as a Limited Company on 15-6-1970. The main aims & objectives of the Federation are:-  To encourage, promote and develop the manufacture of glass articles of all kinds and to safeguard and protect the interests of glass industry and glassware business in India.  To form a common link amongst Glass Manufacturers' in India and thus develop a spirit of mutual help and cooperation with one another.  To promote the study and research in Glass Technology.  To consider all matters relating to the manufacture and marketing of glass articles in India and the question of export and import thereof.  To devise ways and means for securing necessary supply of raw materials required for the manufacture of glass articles at comparatively lower prices and thus to decrease the cost of production and increase the national wealth.  To collect necessary information and data and propagate it for the benefit of Glass Industry and trade in India.  To make representations whenever necessary to the Union Government or any unit of the Union of India for the removal of difficulties that might hamper the trade of glass articles or for grant of special facilities for the Glass Industry.  To draw Government or public attention to the difficulties in the way of Glass Industry and to solve other problems confronting it and to solicit their help and support through concerted action.  To organise a united front on behalf of all glass manufacturers and thus strive to gain all those advantages which may not be possible through individual effort. All those engaged in the manufacture of glass and glass articles are enrolled as Ordinary Members of the AIGMF and those associated with the Glass Industry are enrolled as Affiliate Members of the Federation. Almost all glass manufacturers including many in the small scale sector are ‘Ordinary’ Members of the Federation. Articles of Association of the AIGMF were amended in September 1992 to enroll foreign companies as Affiliate Members of the Federation ■

Kanch | Vol. 6 | No. 1 | April-June 2018 51 [email protected] | www.umdaengg.com

Mr. M.D. Farooq (Founder)

Manufacturer Of Energy Efficient Lehrs

Mr. M.D. Farooq, the founder of Umda Enginering, brings to the table more than 35 years of expertise in the manufac- turing industry. Starting from humble beginnings, today more than 350 of Mr. Farooq’s Lehr machines are successfully installed around the world.

Mr. Farooq is best recognised as one of the co-founders of TNF Engineering, a company known across the industry as not only the leading manufacturers of Metallic Wire Conveyor and Lehr belts but also of Glass Plant Equipment. This mantle of superior performance and expertise has now been passed on to Umda Enginering. Belts A y e m a 2 0 1

Office & Works Plot No. A – 581, TTC Industrial Area, MIDC Mahape, Navi Mumbai – 400 710. MS. India. Tel. 022-2778 20 41/42, Fax : 022-2778 13 38 www.aigmf.com Raising our Glasses to the Glass Industry

Glass containers are by far the most hygienic and environment- friendly receptacles for food and beverages. Moreover, as a packag- ing material, glass is unparalleled in its ability to preserve the taste of the product – and, of course, bottles of all sizes allow for unique and beautiful designs. The Ger- man glass container industry is undoubtedly one of the most inno- vative players in the glass industry. It also uses a large proportion of recycled glass and has a high level of energy efficiency in its manufac- turing processes, so that it clearly The 2017 German Packaging Award in Gold went to Wiegand-Glas for its characteristic meets the need for sustainability. Franconian Bocksbeutel wine bottle. A truly successful design that shows how an instantly At the same time glass businesses recognisable traditional product can be turned into something contemporary. respond flexibly to new trends and (Photo: Haus des Frankenweins Frankenwein-Frankenland GmbH) requirements. cate wineglasses and a fine bottle of can make statements, and they are So what are the latest innova- wine on the table. Container glass is hygienic. Food and beverages pack- tions and developments in the just as much part of our daily lives as aged in glass retain both their taste glass industry? glasstec 2018 in clothes and other day-to-day items and freshness, as glass containers do Düsseldorf has the answer. – and in fact not just in the form of not pass on any taste or impurities to A festive dinner in a smart restaurant glasses, bottles and food containers. their contents. This special quality is would be incomplete without deli- The German glass industry also pro- immensely important, particularly in duces thousands of different con- the food industry, and experts there- tainers for the cosmetics industry, fore describe glass as inert. It’s what the pharmaceutical industry and makes this material unique, and it’s a numerous other applications. quality which consumers clearly value. Moreover, many container glass According to a European-wide study The beer bottle company manufacturers are global play- commissioned by the European Con- Owens-Illinois (O-I) is the tainer Glass Federation, glass packag- world’s first glass packaging ers, and are present not only in ing is greatly appreciated throughout manufacturer to receive Germany, but also in other Euro- society because it preserves the taste gold certification for material pean countries and in the United of the content, is healthy and does not health under the Cradle- States, making a wide range of to-Cradle® standard. harm the environment. glass jars, colourful vases, sterile Their design of the MyPour bottle, aimed at craft and medicine phials and artistically de- FROM A LUXURY PRODUCT gourmet brewers, has an signed perfume flacons. TO AN EVERYDAY ITEM – asymmetrical bottleneck, Glass containers fulfil a wide THE VICTORY OF GLASS so that the pourer can CONTAINERS creatively influence the way range of different requirements. the beer runs into the glass. They can convey a specific im- Container glass can look back to (Photo: Owens Illinois) age through their shape, they a long and indeed eventful history.

Kanch | Vol. 6 | No. 1 | April-June 2018 53 Small flacons could be found in the swathes of tombs of the earliest civilisations, plastic waste yet the manual production process in the world’s remained highly complex until the oceans, causing late Middle Ages, so that glass was painful deaths reserved for the more privileged to fish and birds. members of society. It was exclusively So the container used for luxury goods such as oils, glass industry essences and perfumes, and people is vehemently did not begin to fill it with drinks until working on much later, when production became ways to modify more efficient with the advent of its products. progressive glassblowing techniques. It does so by 17th century Italy stands out especially adding the with its artistic glass manufacturing, largest possible continually surpassing itself in the proportion of recycled production of carafes, bottles and Coca-Cola once led the way, and bottle design is still considered glasses. The final victory of container glass, achieving to be a major feature of many brands. This is also true for Absolut glass came through industrialisation smart savings in Vodka. in the 18th and 19th centuries, and weight, setting (Photo: Absolut Company Pernod Ricard) it has been marked by continuous up sophisticated energy recovery from hot waste gas improvements in production and supply chains and creating stylish which allows so-called pre-heating shape to the present day. designs, all aimed at giving it a technology and therefore saves 10 to contemporary image. THE GERMAN CONTAINER The success of GLASS INDUSTRY: these endeavours INNOVATIVE, CREATIVE AND can be seen, for EFFICIENT instance, in the Today’s demands on the production 2017 German and shape of container glass are Packaging Award focusing increasingly on individuality which went to and specific designs. Production Wiegand-Glas for a quantities are smaller, as is the weight new youthful design of each bottle, yet the containers are of the traditional of a high quality while also meeting Bocksbeutel climate change targets. Another wine bottle used element that has substantially for Franconian impacted manufacturing processes wine – a highlight is the responsible use of resources created in a joint through recycling. Paradoxically, the project between container glass industry has been the designer increasingly impacted by competition Peter Schmidt and from PET bottles, forcing it to the Franconian find solutions which are now also Winegrowers’ important to the end customer. Association. The Furthermore, this focus on the company is equally hygienic and inert qualities of glass has innovative in its Glass recycling is an important element of sustainability in been accompanied by an increasing contemporary and the container glass industry – along with its multiple re-use, awareness of the environmental efficient production allowing bottles to be refilled up to 50 times. dimension, with images of gigantic process, with its (Photo: glasaktuell)

54 Kanch | Vol. 6 | No. 1 | April-June 2018 www.aigmf.com

15% in primary energy. The melting easily diminish any en- temperature required for processing vironmental awareness, can be reached much faster, leading in favour of PET bottles. to a higher base temperature and However, this criticism thus a higher daily melting capacity. has long ceased to be rel- Another successful company with a evant. Thanks to light glass similar design focus and environmen- technology, the container tal awareness is O-I (Owens-Illinois). glass industry is in a posi- Their beer bottles made them the tion to reduce the weight first glass packaging company any- of different types of glass where in the world to receive gold packaging by up to 40%. certification for material health under A one-litre German Hock the Cradle-to-Cradle® standard. In bottle, for instance, now this context, it is also worth mention- only weighs 345 grams, ing the MyPour design, which targets compared with 600 grams the growing sector of craft and gour- – nearly twice as much – 40 years ago. And yet this has not diminished the strength of the bot- Modern production plant of Wiegand-Glas - the company tle, as optimised uses the energy contained in the hot exhaust gases and design has made it thus saves 10 to 15 % of primary energy. possible to achieve (Photo: Wiegand-Glas) a more uniform wall thickness. It’s an advan- out compromising quality. Moreover, tage that makes such bottles the level of social acceptance is unpar- alleled for glass recycling. Germany much lighter, although their alone has around 300,000 waste glass lower weight also leads to sub- containers, which collect about 2 mil- stantial savings in raw materials lion tonnes of waste glass per year. In and energy, optimises handling 2014 the recycling rate was 89%. Yet and reduces transport costs. when we throw our bottles into the relevant recycling container, we may WASTE GLASS CREATES not be aware that one tonne of recy- SUSTAINABILITY – AND cled glass saves over 300 kg of carbon GLASS RECYCLING IS dioxide emissions in the production of met beer brewers. The asymmetrical HIP new glass packaging. bottleneck is diagonal to the rest of One unbeatable benefit of a glass Glass packaging is therefore not the bottle, making it possible to con- bottle is its double potential in terms only one of the most hygienic and trol the head of foam. Depending on of container recycling, as it can be beautifully designed packaging the rotation and angle of the bottle, refilled up to 50 times before being solutions for drinks, food, per- the pourer can influence the way the recycled as waste glass and then fed fume, cream and medicine, but also one of the most sustainable beer runs into the glass. back into the production process. At in the market. The latest innova- the moment the average proportion tions and unusual designs in the WEIGHTY BENEFITS OF of “waste” glass is around 60%, and container glass industry can be LOSING WEIGHT in fact up to 97% for the less popular admired at Messe Düsseldorf's The argument that is often put for- green glass. Glass can be melted down glasstec this coming October. So ward by consumers is the weight of any number of times and turned into do please come along – let’s raise a glass bottle – a criterion which can new high-quality glass packaging with- our glasses to the glass industry 

Kanch | Vol. 6 | No. 1 | April-June 2018 55 WE ARE GLASS PEOPLE

SMART INSPECTION SOLUTIONS

SIMPLY MAKING GREAT GLASS WITH HEYE SMART SOLUTIONS PORTFOLIO

Heye PlantPilot for data integration of Hot End and Cold End SmartLine inspection machine with innovative non-contact features Innovative self-learning systems Smart retrofit packages to upgrade existing machines

56 Kanch | Vol. 6 | No. 1 | April-June 2018 www.heye-international.com

RZ_HEY_ANZ_SMART_INSPECTION_2017.indd 1 04.12.17 15:39 Order Print Copies: ` 500 300 (within India, including postage)

Price: Technical Articles Overseas: US$ 60 40 (including postage and bank charges) GlASSGl ASS - A Sustainable Building and Packaging material

An Publication Prof. (Dr.) A. K. Bandyopadhyay

www.aigmf.com

812 NEW DELHI HOUSE, 27 BARAKHAMBHA ROAD, NEW DELHI-110001, INDIA Telephone: + 91 11 23316507 Fax: + 91 11 23350357 E-Mail: [email protected] Website: www.aigmf.com

812 NEW DELHI HOUSE, 27 BARAKHAMBHA ROAD, NEW DELHI-110001, INDIA Telephone: + 91 11 23316507 Fax: + 91 11 23350357 E-Mail: [email protected] Website: www.aigmf.com Regd. No. R.N. DELBIL/2013/51338 Quarterly Journal of The All India Glass Manufacturers’ Federation, 812 New Delhi House, 27 Barakhamba Road, New Delhi – 110001, INDIA | [email protected]