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Relevance of Cullet Quality to Glass Container Manufacturing

Relevance of Cullet Quality to Glass Container Manufacturing. C. Philip Ross Glass Industry Consulting Glass Packaging Institute CRRA Rancho Mirage, CA August 4, 2009 .

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Relevance of Cullet Quality to Glass Container Manufacturing

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  1. Relevance of Cullet Quality to Glass Container Manufacturing C. Philip Ross Glass Industry Consulting Glass Packaging Institute CRRA Rancho Mirage, CA August 4, 2009

  2. GPI is the trade association representing the North American glass container industry Glass Packaging Institute • 12 member manufacturers • 34 associate member supplier companies

  3. 51 U.S. Glass Container Manufacturing Plants in 23 States • State# Per State • Pennsylvania 6 • California 5(Los Angeles, Oakland, Tracy, Modesto, Madera) • Indiana 4 • Georgia, Illinois, New Jersey, 3 • North Carolina, Oklahoma • Colorado, Missouri, New York, • Virginia, Texas , Washington 2 • Arkansas, Florida, Louisiana, 1 • Massachusetts , Michigan, Minnesota, • Ohio, Oregon, Wisconsin

  4. 2008 U.S. Glass Container Shipments & Production Source: U.S. Dept. of Commerce, Bureau of the Census Data reported in thousands gross. One thousand gross = 144,000 Jan. – May 2008 vs. 2009 Production - Down 6.1 %

  5. 2008 U.S. Glass Container Shipments by Category Nearly 80% of glass container shipments are for beverages

  6. Environmental Benefits of Using Recycled Glass • Over a ton of natural resourcessaved for every ton of glass recycled • Energy costs drop about 2-3% for every 10% cullet used in the manufacturing process • Six tons of recycled container glass used reduces one ton of carbon dioxide • Glass has an unlimited life; can be recycled again and again

  7. 2007 U.S. Glass Container Recycling • 34.5% of beer and soft drink bottles (up from 30.7% in 2006) • 15% of wine and liquor bottles • And 28.1% of all glass containers (up from 25.3% in 2006) (Source: U.S. EPA)

  8. Glass Container Manufacturers Initiative 50% Recycled Content by 2013 • Objectives: • Encourage closed loop recycling • Conserve energy • Save raw materials • Reduce CO2 emissions • Protect environment • Lower Manufacturing Costs

  9. 50% Recycled Content by 2013 Achieving the Goal • Support single-stream curbside recycling best practices • Expand dual-stream curbside collection and drop-off • Expand on-premise bar-restaurant-and-hotel collection programs • Improve beneficiation technology • Accelerate support of legislative initiatives • Build on current deposit programs

  10. Glass Recycling: Critical Issues • Availability • Cost • Quality

  11. Glass Recycling: Critical Issues Energy Reduction • Demand from other glass sectors to reduce energy costs • Need to meet enhanced regulatory standards for air emissions Competition for cullet • Container glass • Fiberglass • Other applications

  12. 2008 Cullet Demand by Glass Container and Fiberglass Producers Approximately 3.35 million tons *Source: O-I North America Glass Co., 2008

  13. Secondary Markets for Cullet • Countertops and floors • Fiberglass • Landscaping • Tile

  14. Secondary Markets for Cullet • Bead • Fluxes/Additives • Frictionators • Abrasives • Brick manufacturing • Roadbed Aggregate - Diversion • Landfill Cover - Diversion • Filtration

  15. Current Cullet Usage Criteria • Container Glass Only: no ceramic coffee cups, drinking glasses, Pyrex, ovenware, mirrors, etc. • Contaminant Free: No ferrous materials, ceramics, etc. • Color Sorted: Clear, Amber, and Green • Meets plant specifications as to particle size (usually 3/8 inch)

  16. Glass Container Manufacturing Virgin Raw Materials and Furnace Ready Cullet

  17. Glass Container Manufacturing

  18. Raw Materials

  19. Glass Melting

  20. Fabrication

  21. Container AttributesColor

  22. Cullet Quality ImpactsRedox – Organics (Paper, Plastics, Food Residue)

  23. Cullet Quality ImpactsMetals

  24. Cullet Quality ImpactsMetals

  25. Cullet Quality ImpactsOther Non-Glass – Foils, Ceramics

  26. Cullet Quality Basics • Glass Containers are Endlessly Recyclable • Other glass types (Window, Tableware, Cook ware) are incompatible with container recycling • Non-Glass Contaminants cause many problems • Color Sorting allows better quality glass containers to be manufactured • Color Sorted (particularly Clear) has more value • GPI’s Glass Manufacturer Members are committed to increasing the use of recycled glass

  27. Choose Glass Recycle Glass www.gpi.org

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