Glass Packaging and Sustainability - Global Approach
Download
Report
Transcript Glass Packaging and Sustainability - Global Approach
Glass Packaging and Sustainability –
Global Approach
Günter Lubitz, Vetropack
Bülach, Switzerland
World Packaging Days 2012, Split, Croatia
Agenda
1. The Vetropack Group
2. Packaging Glass
3. Sustainability at Vetropack
3.1. Economical
3.2. Social
3.3. Ecological
3.3.1. Use of Cullet (recycled glass)
3.3.2. Batch (raw materials) and Cullet Preheating
3.3.3. Lightweight Technology
3.3.4. Hardglass
4. Summary
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 2
1. The Vetropack Group
7 plants
4.2 bn unit sales
589 m CHF gross revenue
59 m CHF annual profit
85 m CHF investments
2,971 employees
Bülach, Vetropack Holding Ltd
Production Plants
CH: St-Prex, Vetropack Ltd
AT: Pöchlarn, Vetropack Austria GmbH
Kremsmünster, Vetropack Austria GmbH
CZ: Kyjov, Vetropack Moravia Glass, a.s.
SK: Nemšová, Vetropack Nemšová, s.r.o.
HR: Hum Na Sutli, Vetropack Straža d.d.
UA: Gostomel, JSC Vetropack Gostomel
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 3
2. Packaging Glass
Made from natural and abundant raw materials
Environmentally safe and 100% unlimited recyclability
Pure, inert, gas-tight ultimate preservation of filled goods
Mix preparation
Furnace
Feeder
Melting into fluid glass
Row materials
Modeling
containers in ISmashine
Hot zone
Quality controll equipement
Packiging
Cooling zone
Packiging materials
Flow chart of production process
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 4
3. Sustainability at Vetropack
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 5
3.1. Economical
Sustainability and long-term economic
success are interdependent
Family company with long-term success before short-term profit
maximization
3.2. Social
Socially committed – from the beginning
Comprehensive health and safety regulations
Meeting employees’ social requirements – irrespective of location
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 6
3.3. Ecological
Manufacturing Process – taking responsibility for our environment
Use of cullet (recycled)
Batch (raw materials) and cullet preheating
Product – taking responsibility for the product and its quality
Lightweight technology
Hardglass
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 7
3.3.1. Recycling Rates in Europe – 2010
Benefits of cullet use
- 2.4% less energy per 10% cullet increase
- 5.5% less CO2 per 10% cullet increase
Effect for Europe
- More than 12m tons of raw materials
conserved
- More than 7m tons of CO2 avoided
Average cullet use of Vetropack
Group is 60%
Source: FEVE
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 8
3.3.2. Batch and Cullet Preheating
Goal: Waste heat from flue gases to preheat raw materials
and cullet
Flexibility regarding cullet ratios (15 – 90% in trials)
Energy input 100%
Source: Zippe
Energy in
glass 48%
Energy in flue
gas 30%
Scource: Horn
Wall losses 22%
Benefits: Preheater works with batch/cullet ratio of only 14%
A full-scale preheater will result in up to 15% energy savings
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 9
3.3.3. Lightweight Technology
Goal: Weight reductions
Benefits:
raw material savings
energy savings
CO2 reduction
smaller carbon footprint
Source: Emhart Glass
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 10
3.3.3.1. Weight Reduction of Wine & Beer Bottles
100cl Bordeaux
75cl Bordeaux
–16% to 420g
–13% to 350g
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 11
33cl Beer
–13% to 165g
33cl Beer
–10% to 185g
3.3.4. Hardglass – Goals and Process
De-palletizer
Bottle
Spacer
Stacker Lehr
Hard Glass
Machine
Cooling
Cold End
Conveyors Coating
Hard Glass
Inspection FlexInspect
Goal – to produce a more robust and/or a lighter bottle
Hardglass – a process to thermally strengthen glass containers
Post process – bottles are heated to 615°C – 650°C
Bottles are lifted from the lehr belt and placed into cooling shrouds
Air enters the shrouds to cool the external surface and
air enters through a tube to cool the internal surface
Glass surface compression stress is generated inside and outside
Tensile stress is generated within the glass
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 12
3.3.4.1. Hardglass Process
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 13
3.3.4.2. What Does It All Mean?
Improvement of mechanical and thermal properties of glass containers
Typical test results
31% increase in average internal pressure resistance
35% increase in average impact strength
significant improvement
in line simulation
in drop test
in vertical load
in thermal shock
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 14
200ml
130gm
3.3.4.3. Drop Test
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 15
3.3.4.4. Drop Test Results – Long Neck Beer Bottle
Filled Drop Results - 209 Gram Beer made on 11/17/2009
45
40
Annealed Pass
Number of Survivors (out of 40 samples per height)
Tempered Pass
35
30
25
20
15
10
5
0
1
2
1.5
32
2.5
4
5
3
Annealed Pass
20
3
2
0
0
Tempered Pass
39
26
17
16
8
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 16
Drop Height (m)
3.5
6
3.3.4.5. Potential for Weight Reduction
1000
900
800
Gewicht in g
700
600
500
400
300
Light Weight
200
Standard Weight
Ultra Light Weight
100
Est. Min. HG Weight
0
0
100
200
300
400
500
600
Inhalt in ml
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 17
700
800
900
1'000
1'100
3.3.4.6. Benefits for End Consumers and Bottlers
More robust packaging glass
Fewer filling line breakages expected
Possibilities for optimizing packaging,
e.g. no cardboard separators
Possibilities for reducing weight of
returnable
non-returnable bottles
Perhaps non-returnable bottles could be used as
returnable bottles (?)
Smaller carbon footprint through weight reduction
Leveraging drop test results – use of packaging glass in stadiums,
vending machines, bars and restaurants, homes ….
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 18
3.3.4.7. Realization and Commercialization
Market launch as joint project between
Installation of most flexible Hardglass post process
48 bottle-per-minute line to be installed at Pöchlarn, Austria
- 2.0 million/month
Ware range
- 100 to 1,000ml
- 50 to 95mm diameter
- 100 to 320mm height under finish
Production start early 2013
Strong interest from Vetropack’s key accounts
2013 & 2014 - Design and build higher-capacity version (≥ 250 bpm)
for in-process production (after forming machine)
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 19
&
4. Summary
Glass Packaging is inert, gas-tight, and ensures taste preservation
It is environmentally friendly with 100% unlimited recyclability
Packaging glass industry has a global sustainability approach
Sustainability covers economical, social and ecological aspects
Use of cullet saves energy and reduces CO2 emissions
Batch and cullet preheating improves energy efficiency for melting
Lightweight technology helps to conserve raw materials and energy
Hardglass is an innovative approach to produce a more robust and
lighter glass packaging and improve its carbon footprint
Container glass is the sustainable packaging material
06.06.2012
Glass Packaging and Sustainability - Global Approach
Vetropack
© VETROPACK | Slide 20