ZeroCO₂

The manufacture of glass is an energy-intensive process that has long relied on fossil fuels. But with mounting pressure from climate targets, regulatory shifts, and growing public demand for sustainability, the industry is on the cusp of a major transformation. Through the ZeroCO₂ Glass project, IPGR aims to develop and test a holistic, carbon-neutral production process for glass.

Innovation driver for a climate-friendly glass industry

The IPGR serves as an international platform and coordinator for pre-competitive research and development, always with the aim of making technical and scientific expertise available to all members. It brings together expertise from around the world and initiates research projects in which alternative raw materials and new energy systems are tested – such as in the ZeroCO₂ Glass project.

At the heart of the project is a specially constructed technology centre, converted from a former warehouse into a modern research facility. “Our pilot plant is a 1:1 replica of a real glassworks on a smaller scale, incorporating all the key process steps involved in industrial glass production,” explains Dominik Orzol, Managing Director of IPGR. Following project planning in 2021, the first construction and conversion work began in 2023, followed by the commissioning of the melting furnace in 2024. After an initial run-in phase, the first trials began in April.

The path to CO₂-free production

The project is employing three strategies to advance CO₂-free glass production. Firstly, it is switching to carbonate-free raw materials that do not generate emissions during melting.

In addition, the energy supply is being reimagined: rather than relying on fossil fuels as before, the plant now uses electrical energy and hydrogen-based heating systems. This combination of alternative raw materials and energy sources can drastically reduce or even eliminate CO₂ emissions from the melting process. The project team is focusing on the shape of the bottles as a third strategy. The aim is to test the new glass composition, melted without CO₂ emissions, for its suitability as container glass. In the future, this will enable the development of lighter bottles that not only save material but also reduce transport emissions.

Technical challenges as an opportunity for further development

The switch to alternative raw materials and energy sources presents new challenges for the entire glass production industry. Carbonate-free glass requires higher production temperatures, placing greater strain on the furnace, preheater, and forming equipment. Innovative materials, adapted forming processes, and, in some cases, new moulding materials are necessary to ensure that existing bottle designs and formats can continue to be produced, as little research has been conducted into how these materials behave under these altered conditions.

Cooperation: the key to success

At the heart of the ZeroCO₂ Glass project is a dynamic partnership between IPGR and leading research institutions – in this case, two specialist departments at RWTH Aachen University. By bringing together experts from glass production, research, and plant engineering, the project creates a unique platform where technical challenges are tackled head-on. Vetropack is a member of the IPGR and is an active participant. Guido Stebner, Chief Technology Officer of the Vetropack Group and Chairman of the IPGR since 2023, plays a pivotal role in this collaboration.

“We are ready!”

Following the completion of the project planning and construction phases, the ZeroCO₂ Glass pilot plant is now fully operational. With the conclusion of the reference phase, the melting furnace has been comprehensively characterised – the project team is familiar with the relevant control levers and now knows exactly where further work is required. This marks the start of the next development phase: trials with higher proportions of electrical energy are planned to achieve the ambitious targets of 50, or even 80, per cent electrification of the melting process in the future.

Three Questions

1. How do you find working together on the ZeroCO₂ glass project?

The collaboration is particularly productive because research, industry, and plant engineering work closely together. This exchange enables scientific findings to be quickly put into practice and technical solutions to be developed jointly. As a result, innovations can be implemented more rapidly and tailored to the actual needs of the industry.

2. What exactly is Vetropack bringing into the project?

Vetropack contributes extensive practical experience in industrial glass production, particularly in glass formulations and the optimisation of production processes. We can also provide first-hand insights into the challenges facing the industry. It is important to us that the solutions we develop are both practical and economically viable.

3. What role do you play in the project as CTO of Vetropack and Chairman of the IPGR?

I see myself as a bridge builder between partners, fostering targeted exchange. The interfaces between research and practice are particularly important – this is the only way to successfully transfer new findings into industrial applications.