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Real-world application

Decarbonization of the glass industry

Sustainability and decarbonization are critical levers for the energy-intensive glass industry. Digital solutions across the glass plant lifecycle increase transparency, improve energy efficiency, reduce emissions and energy costs, and boost manufacturers’ competitiveness.

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Technician monitoring automated glass bottle inspection equipment on a production line in a glass manufacturing facility.

Challenge

Glass producers face multiple challenges on the path to a sustainable future. Increasing energy efficiency, using renewable energy and resources effectively, and reducing energy costs and the CO₂ footprint are key priorities. Employee awareness and compliance with legal and regulatory requirements, including ISO 50001, are also essential for sustainable and efficient operations.

Solution

Digitalization is a key enabler for the sustainable transformation of glass manufacturing. Software, automation and IoT technologies connect data, processes and equipment across the glass lifecycle. Our solutions focus on renewable and clean energy use, energy efficiency, process optimization, recycling, and equipment and facility efficiency, providing a holistic approach to sustainable glass manufacturing.

Benefits

A holistic approach to decarbonization creates benefits that go beyond reducing emissions. Better use of data helps glass manufacturers make informed decisions and improve their overall performance.

  • Increase transparency across the plant and enterprise
  • Improve energy and plant efficiency
  • Reduce energy costs and CO₂ emissions
  • Strengthen competitiveness
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How to get started

Glass manufacturing is energy-intensive, rising energy prices impact profitability, and the energy transition is a major challenge for the entire industry. How can glass manufacturing be decarbonized while increasing productivity and plant efficiency? Explore the key areas of action.

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Renewables and energy efficiency

Reduce energy costs and emissions by using renewable energy and improving energy efficiency. Analyze on-site energy systems holistically with a digital twin, use solar and wind power, increase electric melting, and consider H₂ and biomethane.

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Process optimization

Optimize furnace control and plant operation with simulation technology, model predictive control and AI applications. Explore optimal operating conditions to improve performance and make production processes more efficient.

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Equipment & facility efficiency

Improve equipment and facility efficiency by leveraging real-time equipment and plant data. Enable preventive maintenance, identify potential issues early and help avoid unplanned plant downtime.

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Digital transformation

End-to-end digital transformation connects workflows across the value chain, from smart procurement and supply chain management to production planning and outbound logistics. Enable IT/OT convergence by connecting ERP and MES systems and creating data transparency from field to cloud.

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Waste heat recovery

Make optimal use of waste heat by converting it into electricity and thermal energy for buildings, batch preheating and other purposes. This helps reduce energy costs and the carbon footprint while making better use of available energy.

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CCUS

Reduce carbon emissions and help limit global warming with carbon capture, utilization and storage (CCUS). By capturing and reusing CO₂, innovative technologies can help accelerate the path toward decarbonization.

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Cullet recycling

Reduce energy consumption and raw material usage by using more cullet in the melting process. Recycling cullet supports a circular economy and helps make glass manufacturing more resource-efficient and sustainable.

IT/OT Integration

Decarbonization relies on granular, plant-wide visibility, but glass manufacturing facilities often run on fragmented operational technology (OT) from multiple equipment vendors.

Digital Twins

Since glass melting is a continuous high-temperature process, operational changes cannot be made via trial-and-error without risking furnace damage or batch defects. Digital Twins are the solution.

Cybersecurity

While using data extensively across the enterprise is necessary to gain transparency, it also increases the potential for cyberattacks. Therefore, protecting your plant is mandatory.

Case studies

Discover how others are approaching their challenges

Glass production facility at Noelle + von Campe
Noelle + von Campe, Germany
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When IT and OT join hands

Noelle + von Campe is the first glass manufacturer to connect SIMATIC PCS 7 with SIMATIC Virtualization as a Service (SIVaaS), complemented by SIMATIC EnMPRO energy management. A prime example of successful IT/OT convergence.