Drive innovation

The Innovation Centre vividly demonstrates that innovation is a highly relevant issue for our company. Under the leadership of Daniel Egger, Group Head of Innovation, the Centre was integrated into our Technology and Production division with effect from January 2022. This organisational change was followed by further expansion, one step at a time. The Innovation Centre in Pöchlarn currently has a workforce of 32 employees. Its structure comprises three units: Process and Technology Innovation, Product and Material Innovation, and Smart Factory Innovation. This rare look behind the scenes reveals exactly what we are researching at this moment in time.

New machine makes bottle tempering more efficient

Vetropack has developed a unique product that is the world’s first returnable bottle made of thermally tempered lightweight glass. It is manufactured using a new process, which involves thermal tempering of the glass bottles. Their low weight substantially reduces logistics effort and expense, while the CO₂ emissions per bottle are down to about one quarter of the rate for a normal returnable bottle. Our goal now is to move nearer towards making this technology ready for industrial use, so we are currently researching a new and even more efficient machine to temper the bottles. A pilot plant to test this redesigned process has already been ordered, and is scheduled to go into production in mid-2024. If the relevant tests proceed as planned, a fully developed version of this machine can be expected as early as the second half of 2025 – leading to a further increase in our production capacities.

Carbon Capture and Utilisation (CCU)

Our Process and Technology Innovation unit is also conducting tests on the use of a promising carbon capture and utilisation technology for the glass industry. This process is known as ‘carbon mineralisation‘, where carbon dioxide is convered into a carbonate. This chemical reaction happens when special rocks are exposed to carbon dioxide. As the carbon dioxide cannot escape back to the atmosphere, this process could be highly interesting for the glass industry – because it could turn CO₂-free glass production into a reality.

‘No Soda’production

Vetropack is a member of International Partners in Glass Research (IPGR), a global research organisation that promotes glass science and technology through collaboration between the industry, colleges and universities, and public authorities. Vetropack is conducting trials aimed at changing the raw material input in a furnace that has been taken out of service. As part of the ‘No Soda Trials’, the mix of raw materials was adapted so as to eliminate the additional use of soda, one of the main sources of CO₂ emissions. The melting behaviour of the mix was examined in a ten-day investigation. The formability of bottles from the soda-free melt was proven successfully at the end of the trial. Our Product and Material Innovation unit is also focusing intensively on alternative mix compositions – i.e. the recipes that ultimately reach the furnaces – and alternative raw materials.

Seamless traceability thanks to advanced data matrix and RFID technology

In our Smart Factory Innovation unit, we are currently introducing a robust traceability system using data matrix codes. Each bottle is given a unique identifier that captures and stores specific data throughout the entire production process. This makes it possible to detect potential problems at an early stage, and it improves quality control – leading to additional transparency which strengthens customer trust. As another benefit, RFID (Radio-Frequency Identification) technology enables us to identify pallets and check their quantities in real time, so logistics and production efficiency are optimised. A hot-end laser marks all thermal tempered products with a data matrix code that stores a vast amount of information and opens up some exciting possibilities. In the event of a complaint, for instance, the products involved can be rapidly identified. It also offers advantages for advertising-campaigns and loyalty programmes.

RFID technology for pallets is already in use at our Pöchlarn, Straža, Nemšová and Kyjov plants. The solution records data for both incoming and outgoing pallets. Going forward, it will be possible to divert individual pallets to external depalletising zones according to defined criteria, and to ensure the traceability of the pallets with the articles.

Continuing the development of machine vision

Computer vision systems leverage deep learning algorithms to process visual data and extract meaningful information. In a factory environment, this technology can be used to recognize objects, patterns, and anomalies in various segments. Vetropack has identified numerous benefits from utilizing this technology, including improved product quality, enhanced efficiency, and reduced downtime. At Vetropack, we utilise computer vision for various applications ranging from advanced inspection of products for defects to quality control – always with the aim of ensuring that our products meet the highest standards. We also use computer vision for article counting, so items are accurately tallied to streamline inventory and production processes. Looking ahead, we see significant potential in expanding the use of this technology. Future possibilities include using computer vision in mould workshops to assist in wear and cleanliness inspections, continuously monitoring the production environment for any irregularities or stoppages to enable quick intervention and minimize downtime, and enhancing warehouse management through improved monitoring and automation. This is just the beginning, and there are many opportunities to continue leveraging computer vision technology at Vetropack.

Digital twins play their part in the digital revolution

This project involves using state-of-the-art technologies such as AI, computer vision, the Industrial Internet of Things (IIoT) and advanced robotics to create digital replicas of for thermal tempering furnaces and testing machines (to name just two examples). These digital twins mirror real-life processes and they open up possibilities for realtime monitoring, simulations and extended data analyses. The benefits: optimised settings, predictive maintenance, and identification of hidden scope for process improvements. Time after time, Vetropack’s relentless research activities continue to position our company at the forefront of intelligent glass packaging. We are excited to see what developments the future will bring.