Glass Futures has partnered with the Grenzebach Group to install an R&D rolled glass line at its pilot facility in St Helens, UK.

The collaboration supports Glass Futures' objective to enhance operational efficiencies within the glass manufacturing sector by driving innovation and sustainability towards net zero.

As part of the initiative, Grenzebach has supplied an annealing lehr, a cutting line, and a control system to enable high-quality and sustainable glass production.

The project is due to be commissioned in the coming months.

Aston Fuller, General Manager at Glass Futures, said: “Glass Futures’ pilot facility offers 30 tons of glass R&D capability per day – the perfect base for our research and with scope to develop a second line, we are focusing on furnace optimisations, emissions, and alternative fuels.”

The newly developed annealing lehr from Grenzebach features heating, cooling, and transport technologies.

It measures 25 meters in length, divided into specialised zones: A, B, C (radiation cooling); E (ambient cooling); and F (forced convection cooling).

Each zone is designed to optimise the cooling process.

The control system accompanying the annealing lehr measures and visualises temperature data along the entire hot and cold end, enabling precision in managing the glass ribbon's cooling and cutting processes.

The integrated cutting system effectively transforms the continuous glass ribbon into custom sizes while minimising waste.

This combination of technologies is engineered to enhance the overall efficiency and quality of glass production processes.

Additional features of the annealing lehr includes:

  • Up to 50-70% less energy consumption (due to lehr configuration): the system's efficient cooling process and improved insulation lower energy usage and emissions.
  • Controlled cooling capacity: individually controllable heating and cooling sections allow for precise adjustments to the process, accommodating changes in production demands.
  • Enhanced glass quality: the design with a flexible annealing zone keeps the internal stresses during glass cooling within an ideal range, producing a high-quality product.
  • Flexible retrofits: Grenzebach's solution allows manufacturers to implement zone-based upgrades in existing production lines, providing enhanced productivity and sustainability while using the same space.

In addition, Grenzebach is looking forward to carrying out its own measurements and research on the Glass Futures' line.

For example, to develop its own software solutions for its digital ecosystem Sericy further.