BEAR
Harnessing innovation, reducing emissions
paving the way towards greener glass manufacturing
About BEAR
The Innovation Fund project BEAR (Hybrid regenerative glass furnace) will demonstrate a first-of-a-kind hybrid end-fired regenerative furnace with an electrical melting share of more than 40 %. The furnace will be implemented at Steklarna Hrastnik’s (SH) existing production site in Hrastnik, Slovenia and has a throughput capacity of 170 tonnes of glass per day.
The hybrid furnace will replace the existing end-fired regenerative furnace for extra-white flint glass production, thereby resulting in over 50% reduction of natural gas consumption and up to 33 % greenhouse gas (GHG) emissions avoidance over the first ten years of operation.
The BEAR project aims to address the energy inefficiency and high carbon footprint associated with the widely used end-fired regenerative furnace in the glass industry. To achieve this, the project is developing a hybrid regenerative furnace that combines the energy efficiency of electric furnaces with the operational flexibility of conventional regenerative furnaces. By increasing the share of electrical boosting from the current 5-10% to over 40%, the project aims to significantly reduce natural gas consumption and avoid emitting 96.384 tonnes of CO2 equivalent greenhouse gases over a ten-year period. This reduction is greater than the total annual household greenhouse gas emissions of the Zasavje region, where the project is located.
Moreover, the electrification of the container glass sector through the adoption of the hybrid regenerative furnace will allow the glass melting process to align with the availability of renewable energy sources (RES). By directly coupling local RES to the melting process, the project not only improves energy efficiency but also enhances the resilience and security of the glass manufacturing process in terms of energy supply. With SH, a significant employer in the coal region of Zasavje, taking the lead in this transition, the project is expected to have a positive impact on the local economy by retaining current jobs and creating new ones. Furthermore, the success of the project in decarbonizing the glass industry can serve as a model for other energy-intensive sectors in the region, inspiring them to adopt sustainable production technologies and contribute to a greener future.
Key figures
COORDINATOR
Steklarna Hrastnik d.o.o. (SH) |
BENEFICIARIES
Kemijski inštitut (NIC) |
LOCATION
Hrastnik, Slovenia |
SECTOR
Glass, ceramics and construction material |
GHG EMISSION AVOIDANCE
96 384 t CO2 eq |
AMOUNT OF INNOVATION FUND GRANT
EUR 2 238 000 |
RELEVANT COSTS
EUR 3 730 000 |
STARTING DATE
1 September 2022 |
PLANNED DATE OF ENTRY INTO OPERATION
Q1 2025 |
BEAR project
The hybrid regenerative furnace will be implemented at Steklarna Hrastnik’s existing production site, Special, located in Hrastnik, Zasavje, Slovenia. The site, which has been in operation since 2005, has an annual production capacity of 37,000 tons. The Special site focuses on manufacturing extra white flint glass for Premium and Super Premium containers. It employs 174 out of Steklarna Hrastnik’s total of 530 employees and accounts for nearly 60% of the company’s sales revenues (2021).
The envisioned hybrid furnace will replace the existing end-fired regenerative furnace at the site, which has a capacity of 165 tons per day. The old furnace, designated as furnace B, was specially designed for low-iron flint glass production and commissioned in 2014. With the implementation of the hybrid regenerative furnace, the electricity share for glass melting will increase from the current 7% to above 40%.
News & events
Igniting Innovation
In the week of 26th-29th Steklarna Hrastnik assessed the baseline performance of its first-of-a-kind end-fired hybrid regenerative furnace within the InnovFund project BEAR.
Inserting measuring probes for flue gas composition in the port necks of the furnace where the temperatures of gases can reach beyond 1500°C.
Electrifying Progress on Project BEAR!
Last week marked a significant leap in our InnovFund project BEAR as we successfully completed our first boosting ramp-up to full hybrid operation. In the week of May 13th, we assessed the enhanced performance metrics of our first-of-a-kind end-fired hybrid regenerative furnace, thereby setting new standards in our industry.
Glass production is an energy-intensive process and is one of the most difficult industrial sectors to decarbonise. Worldwide, 75% of container glass is produced in so-called “end-fired regenerative furnaces” which rely heavily on fossil fuels. Less polluting technologies, such as electric furnaces, are available but have a shorter lifespan. Now, thanks to a €2.2 million grant from the Innovation Fund, the BEAR project is set to revolutionise this landscape by creating a new type of furnace that combines the best of both technologies.
This state-of-the-art furnace will replace the traditional design with a more energy-efficient and semi-electric functionality. The result will be a hybrid, end-fired regenerative furnace that sources electricity for 40% of its heat supply, surpassing the maximum 10% limit in a traditional furnace. The electricity will be produced from renewable sources and marks a substantial step forward in sustainable glass manufacturing.
The furnace started its baseline operations in January 2024, already producing up to 170 tonnes of container glass per day and sourcing 15% of its heat supply from electricity. The hybrid furnace is expected to be fully operational by early 2025, reaching its targeted electric share of 40%. This will allow the production site to reduce its natural gas consumption by over 50% and avoid almost 100,000 tonnes of carbon dioxide (CO2) equivalent over the first ten years of operations. This reduction is enough to offset the total yearly greenhouse gas emissions of 20,000 households in the Zasavje region.
With the BEAR project, the parent company Steklarna Hrastnik aims to replace its existing regenerative furnace for extra-white flint glass production at one of its two sites. Both production sites are in Zasavje, a transitioning coal region in Slovenia with a high unemployment rate. Steklarna Hrastnik accounts for roughly 5% of jobs in the region and represents over 10% of the region’s GDP. By investing in sustainable production technologies, the BEAR project is expected to have a great impact on the local economy by not only maintaining current jobs, but also creating new ones.
By coupling innovative technologies with local renewable energy sources, the project will also serve as a decarbonisation model for other energy intensive industries in the EU. In addition to the use of renewable electricity, hybrid furnaces could also use biogas and hydrogen from renewable electricity as sustainable energy sources to transition the glass sector towards a climate neutral future.
Overall, the BEAR project demonstrates how innovative technology can drive significant environmental and economic benefits. By integrating traditional and electric furnace technologies, this project is setting a new standard for sustainable glass production.
About the Innovation Fund
Funded by the EU Emissions Trading System, the Innovation Fund focuses on groundbreaking projects that significantly reduce greenhouse gas emissions. It is one of the world’s largest support programmes for the deployment of net-zero and innovative technologies. The support from the Innovation Fund has been instrumental in helping the project reach financial maturity earlier, ensuring that its benefits extend beyond Steklarna Hrastnik to the broader European community and the environment.
Exciting news!
We’re thrilled to unveil our brand-new subpage dedicated to our EU-funded endeavors to decarbonize glass manufacturing!
Innovation and sustainability drive everything we do at HRASTNIK1860, and this platform highlights the pioneering projects that are helping us shape a greener future for the glass industry. From breakthrough technologies to clean energy initiatives, these projects represent our unwavering commitment to driving transformative change.
What can you explore on the new subpage?
✨ Projects i-STENTORE and CITADEL, which build on the foundation laid by our flagship InnovFund project BEAR and its first-of-its-kind hybrid regenerative furnace, advancing both energy storage and electrification.
✨ Our work on hydrogen as a clean energy vector for glass production:
H2GLASS: Proving industrial feasibility of hydrogen-powered glass production.
NAHV – North Adriatic Hydrogen Valley :Creating a cross-border hydrogen ecosystem.
PHOTOSINT: Developing novel technologies for efficient hydrogen production using advanced electrocatalysis.
These projects are part of our vision for a carbon-neutral, highly efficient glass industry, and they’re made possible through collaboration, creativity, and cutting-edge science.
Want to learn more about how we’re pushing the boundaries of what’s possible in the glass industry?
Check out our new projects page here: Projects | Hrastnik1860
Insights from the Sustainability Roundtable | Vaider Group Sustainability Conference, a special event to commemorate CINEA – European Climate, Infrastructure and Environment Executive Agency InnovationFund project BEAR
Today’s Sustainability Roundtable brought together key leaders from across the glass value chain to tackle pressing questions about sustainable transformation and its challenges.
Panelists:
Jean-Pascal MARTIN-FESTA (CPO Rémy Cointreau): Sustainable glass offtaker.
Dirk Schnurpfeil (Nikolaus Sorg GmbH & Co. KG): Furnace technology provider.
Dr. Rok Lacko (GEN-I, d.o.o.): Clean electricity provider.
Primož Urek (Messer Group, Inc.): Hydrogen technology expert.
Dr. Janvit Teržan (Kemijski inštitut – National Institute of Chemistry ): Public research advocate.
Matevž Fazarinc (CEO of Hrastnik1860): Sustainable glass producer.
Moderator: Frans Joziasse, PARK
Key Topics Discussed:
Sustainability vs. Cost Perception: How to overcome the hesitation caused by viewing sustainability as a cost driver and align it with consumer willingness to pay.
Collaborative Achievements: Hrastnik1860 shared its journey to sustainable glass production, emphasizing the importance of partnerships across the value chain.
Organizational Governance: Panelists explored management’s critical role in embedding sustainability into business practices.
Benefits Beyond Sustainability: Insights into how sustainable transformations deliver additional value to customers and consumers.
Future Challenges: From regulatory hurdles and clean energy distribution to financing green transitions, the panelists addressed the barriers to achieving carbon neutrality.
Takeaway: The glass value chain proves that collaboration, innovation, and strong governance are vital to transforming sustainability challenges into opportunities.
Highlights from the Vaider Group Sustainable Week event
- The BEAR Hybrid Furnace: At the heart of the event was the launch of our latest technology HyBrid rEgenerative glAss fuRnace (BEAR). Co-financed by by CINEA – European Climate, Infrastructure and Environment Executive Agency under the InnovationFund, this first-of-its-kind furnace sets a new benchmark for sustainability in glass production by reducing emissions and utilizing green energy.
- RE.Vine Wine Bottle Unveiled: We proudly showcased the RE.Vine bottle, an innovative collaboration with J.RE. This premium wine bottle combines reduced weight, hybrid energy, and post-consumer recycled material to achieve 100% carbon neutrality—leading the way in sustainable wine packaging.
3.Sustainability Roundtable: Key leaders from the glass value chain came together to share insights on overcoming challenges and driving sustainable transformation, emphasizing collaboration, governance, and innovation.
Together, these milestones mark a bold step toward a greener future for the glass industry.
Leading the Way in Decarbonization with the New Hybrid Furnace
We are proud to announce the entry into operation phase of one of our most significant sustainability projects—the HyBrid rEgenerative glAss fuRnace (BEAR)
What does this groundbreaking project bring?
- More than a 50% reduction in natural gas consumption for melting.
- Up to a 33% reduction in greenhouse gas emissions.
- 100,000 tons of CO₂ savings in over the furnace lifespan – equivalent to the annual carbon footprint of 20,000 households in the Zasavje region.
The new hybrid regenerative furnace, developed under the InnovationFund BEAR project, is the first of its kind and co-financed by CINEA – European Climate, Infrastructure and Environment Executive Agency. It sources green electricity for up to 40% of its heat supply, enabling a sustainable production transition without compromising quality.
Why does this matter?
- The hybrid furnace introduces sustainable innovations for reducing emissions and improving energy efficiency.
- It positions Hrastnik1860 and the Vaider Group as leaders in the green transition of the glass industry.
- Commitment to a sustainable future with a greater reliance on renewable energy.
Let’s continue pushing boundaries toward a sustainable tomorrow.
Project results
List of public deliverables of the project:
- D.1.3: Minimum communication requirements
- D1.6: PU Knowledge sharing report
- D2.1: Update to PU knowledge sharing report
- D3.2: 2nd update to PU knowledge sharing report
- D6.1: 3rd update PU knowledge sharing report
Project partners
Steklarna Hrastnik (SH) is a global leader in glass manufacturing, with a focus on high-quality and sustainable products. With over 160 years of experience, SH exports 98% of its glass products to more than 50 countries worldwide. Their products range from traditional to award-winning innovative designs, made from top-quality glass that is free of heavy metals. SH offers customization options and prides itself on flexible service, fast time to market, and tailor-made solutions. They are committed to continuous improvement, technological innovation, and environmental sustainability, positioning themselves as drivers of green innovation in their industry and beyond.
Kemijski inštitut (NIC) is a leading Slovenian research institution specializing in chemistry and related disciplines. Their research focuses on areas of long-term significance, such as materials research, life sciences, biotechnology, chemical engineering, structural and theoretical chemistry, analytical chemistry, and environmental protection. This aligns with the needs of both domestic and international industries, including pharmaceuticals, chemicals, automotive, and nanobiotechnology. The Department of Catalysis and Chemical Reaction Engineering at NIC is specifically involved in chemical engineering, reactor design, process modelling, and construction. Leveraging their extensive experience in developing decarbonized solutions, the department will contribute to advancing hybrid furnace technologies and the use of carbon-neutral energy sources. The department’s expertise is well-suited for tasks such as accelerated aging tests for catalyst stability, comprehensive characterization, digital twin modelling, and techno-economic assessments.
Get in touch with BEAR team
Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or European Climate, Infrastructure and Environment Executive Agency (CINEA). Neither the European Union nor the granting authority can be held responsible for them.