In a groundbreaking development for the glassmaking industry, Ardagh Glass Packaging-Europe has announced that its NextGen Furnace has consistently achieved a 64% reduction in CO2 emissions while producing glass bottles. This milestone marks a significant step towards sustainable glassmaking and sets a new standard for the industry.
The NextGen Furnace, located at AGP-Obernkirchen in Germany, has been gradually increasing its reliance on direct electrical heating through electrodes since its commercial production began in October 2023. The ultimate goal is to achieve 80% electrical heating and 20% gas usage. In 2024, the furnace has maintained an average rate of 60% electrical heating, thanks in part to the support and expertise provided by SORG, the furnace supplier.
This innovative furnace has been made possible through funding from the BMWK's 'Decarbonisation of Industry' programme, managed by the KEI, and the 'NextGeneration EU' European Innovation Fund. The NextGen Furnace pushes the boundaries of electric melting technology, capable of producing up to 350 metric tons of amber glass using up to 70% recycled glass cullet.
Joris Goossens, R&D Project Manager at AGP-Europe, acknowledged the challenges faced during the process, stating, "Ramping up the electrical heating in the NextGen Furnace has not been an easy journey. In a conventional furnace, the combustion space is hotter than the glass, but in the NextGen Furnace, the glass gets hotter than the combustion space: the furnace is effectively upside down. We have been navigating uncharted territory."
Sven-Roger Kahl, Manager of Furnace Operations at AGP-Europe, added, "The NextGen design, which features electrodes in the bottom of the furnace, has challenged traditional furnace operating rules. It has been like learning to drive again, but it has been worth the effort to reach our goal of low-carbon glass packaging."
The NextGen Furnace has attracted attention from key customers, glass industry peers, suppliers, and government officials who have visited the facility to witness its operation firsthand. Discussions have also taken place regarding the need for electrical grid connections to facilitate the adoption of this technology at other AGP facilities.
AGP-Europe plans to implement hybrid and other sustainable melting technologies for furnace rebuilds from 2027 onwards, contingent upon the availability of appropriate electrical infrastructure in the relevant markets. This commitment to sustainable practices is expected to drive significant reductions in CO2 emissions across the glassmaking industry.
