After a big success last year, when Hrastnik1860, a premium glassmaker and member of Vaider Group, successfully pioneered the commercial production of premium glass spirits bottles using hydrogen as the primary energy source*, the company continues with breakthrough innovations. Hrastnik1860 is proud to announce a new significant innovation in the glass industry: they will be the first to utilize a hybrid regenerative glass furnace with an increased electric melting share. By doing so, they remain firmly committed to their sustainability promises, as the new furnace will drastically reduce greenhouse gas (GHG) emissions, setting a new standard for sustainability in glass manufacturing. They are already collecting customer orders for decarbonised production, hybrid and hydrogen melting, during their Sustainable Week’ this December.
“Sustainability is a key part of Hrastnik1860’s business development strategy, with innovation being at its forefront. Currently, we have 10 active R&D projects focused on sustainable innovations, including 6 international ones. Among the most important are the electrification of glass melting and hydrogen-fuelled glass melting. We are proud to be pioneers in both areas within the sector,” said Matevž Fazarinc, CEO of Vaider’s Hrastnik1860. As an energy-intensive company, they pay special attention to environmental sustainability and have very clear plans for decarbonizing our production, using recycled materials, and producing more sustainable glass. “We have already implemented many measures, and since 2020, we have reduced our overall carbon footprint by 48 percent,” added Fazarinc.
Within the BEAR project*, co-funded by the Innovation Fund, Hrastnik1860 aims to revolutionise the end-fired regenerative furnace design through hybridisation. Particularly, the project aims to increase the energy share of electrical boosting from the conventional 5-10% of end-fired regenerative furnaces to 40%. This will enable Hrastnik1860’s production site to reduce its natural gas consumption and related GHG emissions by more than 50%
The hybrid regenerative furnace combines the all-electric and regenerative furnace concept, aiming to best utilize the advantages of both furnace technologies and diminishing their drawbacks. Namely, this cutting-edge technology makes it possible to use carbon neutral energy sources while maintaining the operational flexibility of conventional regenerative fossil-fuel furnaces. To demonstrate theses abilities, Hrastnik1860 will, within the Horizon Europe project i-STENTORE*, couple the hybrid regenerative furnace with a local PV power plant into a so-called Hybrid Energy Storage System (HESS). The aim is to use the molten glass within the furnace as an energy storage unit when surplus energy is available from renewable energy sources (RES), thereby aligning the glass melting process with the availability of renewables. To further increase this potential, Vaider’s Hrastnik1860 will strive to increase the electric melting share beyond the 40%, targeted by BEAR, to super hybrid melting. These activities are also co-funded by the EU within the project CITADEL*, which tackles the electrification of high-temperature process with innovative technologies.
This forward-thinking approach demonstrates Hrastnik1860’s commitment to a greener future, leveraging advanced technology to minimize their carbon footprint. The hybrid regenerative furnace represents a major step toward their goal of reducing environmental impact while maintaining high production quality. As industry leaders in terms of innovation in sustainability, Vaider’s Hrastnik1860 is dedicated to pursuing its vision to be the most inspiring and sustainable glass packaging company on the planet.
How to significantly lower emissions without jeopardizing quality?
Another significant step towards a greener future is the use of recycled materials in the production of premium bottles. This was, as Fazarinc explained, previously impossible due to customer demands for the purest glass for their premium beverages. Until recently, they only melted high-quality so-called ‘extra white flint’ glass, which requires the purest raw materials, and the use of external recycled glass in production was not possible. “However, we are seeing changes in market demands and trends, leading to a call for the inclusion of recycled glass in production processes even for the highest quality glass packaging. Although recycled glass, if not of the highest quality, can impair the aesthetic appearance of products, end consumers are willing to compromise between sustainability and quality,” explained Fazarinc.
Vaider’s Hrastnik1860 plans to produce ‘super flint’ glass packaging, integrating recycled content to enhance environmental sustainability and resource efficiency. Utilizing post-consumer recycled (PCR) glass can save up to 300 kWh per ton of energy, lowering the energy demand for glass production. By incorporating up to 40% PCR, they aim to reduce their direct GHG emissions by approximately 35%, and overall cradle-to-gate emissions by 27%.
This energy saving is crucial in reducing the overall carbon footprint of the industry, as less fossil fuel is required to melt recycled glass compared to raw materials. In terms of raw material savings, incorporating PCR glass can substitute up to 1,200 kg of raw materials per ton of PCR used. This not only conserves natural resources but also minimizes the environmental degradation associated with raw material extraction and processing. By leveraging the benefits of recycled glass, the company not only enhances its environmental performance but also paves the way for a more sustainable future in the glass industry.
Reducing the weight of the bottles contributes to sustainability and cost efficiency
“Another important feature available to our customers are lighter bottles which significantly contributes to sustainability by reducing energy consumption, water usage, and GHG emissions,” explained Fazarinc. Lightweight bottles require less raw material which decreases the energy needed for production. This reduction in energy translates to lower operational costs and less strain on energy resources. Furthermore, producing lighter bottles consumes less water, a critical factor in conserving this precious resource.
Lightweighting also significantly improves the transportation efficiency as more lightweight bottles can be loaded onto a single truck, maximizing transportation capacity and reducing the number of trips required. This optimization lowers fuel consumption and associated emissions, making the logistics chain more eco-friendly. By implementing bottle lightweighting, Vaider’s Hrastnik1860 is improving its environmental performance as well as achieving cost efficiencies, resource conservation, and logistical improvements.
“Thinking beyond profits, Vaider’s Hrastnik1860 is showcasing its commitment to invest in a more sustainable future. Despite higher costs associated with hybrid furnace technology, we believe that environmental stewardship is paramount. This innovative approach not only demonstrates leadership in sustainability but also sets a new standard for the glass industry. Hrastnik1860 is dedicated to advancing greener production methods, ensuring a healthier planet for future generations,” emphasized Fazarinc.
* 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 granting authorities. Neither the European Union nor the granting authorities can be held responsible for them.
