1. BENEFITS OBTAINED WITH “READY FOR PRODUCTION”
GLASS BATCH
Tony Butt / Chemson Group
Graham Brooks / Industrial Analysis Limited

2. Advantages in Production and Logistics Savings using Prilox Quality
Content
Introduction
Advantages in Production and Logistics
Savings using Prilox
Quality
Furnace Benefits
Summary

3. Prilox ® S provides a way forward for the future
Introduction
Market conditions for crystal glass
Stagnation in the glass markets
Short production forecasts
Flexibility required
Demand for capital investements
Ever increasing environmental pressures
High Pressure on all glass companies
Each glass producer has to consider its own strategy to deal with these issues
Prilox ® S provides a way forward for the future

4. Introduction
Chemson originally launched Prilox ® at the ICF conference in Salzburg in 2000
Two notable producers –
Waterford since 1999
Inn Crystal since 2001
Chemson presented a summary of Benefits at the ICF conference in Siena in 2001
This presentation now re-confirms the previous results and provides further evidence of the advantages of pre-blended glassbatch

5. Advantages in production
Advantages in Production and Logistics
Advantages in production
Prilox ® – Two components
Prilox ® S – One component
Auto handling of batch
Eliminates batch house problems
Reduced number of raw materials
Higher cullet ratio can be used
Increased melting rate flexibility

6. Savings using Prilox ® Energy Environment Savings using Prilox ®
Reduced batch house handling and mixing
Higher cullet ratio
Higher energy efficiency in melt process
Reduced exhaust air
Environment
Reduced waste, less dust
Reduced disposal costs
Better working conditions, reduced exposure
for employees

7. Energy consumption Measured by Inn Crystal
Savings using Prilox ®
Energy consumption Measured by Inn Crystal
Better homogenous batch
A closed batch blanket
Higher flexibility output
Higher cullet ratio can be achieved
Reduction of the overflow
A shorter melting time
Achieved an energy saving of more than 10%

8. Furnace Inn Crystal
without Prilox ®
with Prilox ®

9. Reduced dust and emissions
Savings using Prilox ®
Reduced dust and emissions
measured results from Inn Crystal
Dust reduction over the furnace > 80 %
Total dust reduction > 65 %
(furnace, batch house, production)
Reduction of the total dust emission after the filter > 50 %
Reduction of the total lead emission after the filter > 85 %

10. Energy reduction Glasstronics experience at Waterford Crystal
Savings using Prilox ®
Energy reduction Glasstronics experience at Waterford Crystal
1995 – with conventional batch
Pull = 20,1 tpd Cullet = 60 %
Power consumption = 595 kW/hr
= 710 kWh/t
1999 – with Prilox ®
Pull = 20,5 tpd Cullet = 65 %
Power consumption = 560 kW/hr
= 656 kWh/t
Achieved an energy saving of 7,5 %

11. Investments and overheads
Savings using Prilox ®
Investments and overheads
Reduce / eliminate batch production costs
and future investment
Reduced costs of personnel due to lower exposure to lead
Reduced insurance risk to employer liability
Reduced investment for environmental reasons
Prolonged life of furnace – to be confirmed
The correct investment strategy could determine your future !

12. Continuous quality Quality …….starts by……
Quality assured to ISO 9001:2000
Controlling all incoming raw materials
Raw material only from approved suppliers
Batch to batch consistency
Quality control tested
No separation during transport
………..and pulls itself like a red line…….

13. Continuous quality Quality ………. and pulls itself like a red line……
For consistency and reliability through the melt process
For a flexible melting rate to assist various product types
Quicker melting process than normal glass batch
Reduced exposure of employees to dangerous goods
Improved total quality of final product
……and stops in a clear and brilliant end product.

14. Furnace benefits Furnace Benefits Higher consistency of glass melt
A reduced erosion of electrodes
approx. 30% reduced wear – Waterford Crystal
constant and improved wear performance – Inn Crystal
Homogenously bonded material melts easier with lower temperature
Smaller bubbles

15. Electrodes – Waterford Crystal
The following picture show the erosion following 4 years
operation with a conventional batch mix and 60 % cullet

16. Electrodes – Waterford Crystal
With changing 3 parameters – conventional batch to Prilox ®, removal of Arsenic and increased cullet ratio – we noted a significantly lower level of erosion of electrodes and refractories following the second 4 year period.

17. Electrodes – Waterford Crystal
For reference: The repaired furnace with new electrodes

18. Summary Summary Prilox ® now has full experience of more than 4 years
Prilox ® S with sand is available
Benefits include
Environmental improvements
Reduced energy consumption
Improved quality
Production efficiency and flexibility
Reduced capital investment

19. Prilox ® (glass batch without sand), Chemson set the first step
Development of Prilox ®
Prilox ® (glass batch without sand), Chemson set the first step
To reach the legal guidelines
health and safety - to reduce the level for lead in blood
environment - lower emissions
To react faster to changed market situation
To provide a solution for the future
A cost acceptable solution
With Prilox ® S – (glass batch with sand) from “glassblend”
Same benefits supplied “ready for Production”

20. Find out more from our exhibition stand.
Development to Prilox ® S
Two strong companies with large experience, both supplier to the glass industry for a very long time.
&
form the Joint Venture
Find out more from our exhibition stand.