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Xcite FHC Technology

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  1. Xcite FHC Technology Ferro Corporation Worldwide Glass Coloring Solutions for Glass

  2. What is FHC Technology? • Introduction, melting and dispersion of colorants in the forehearth channel instead of the glass tank • Allows one or more forming machines to produce individual colors without a full tank changeover • So, a flexible color operation can be created without sacrificing the economies of large scale tank production • Almost all tank colors can be made also by FHC

  3. Xcite FHC Technology Delivers…….. • An alternative technology for colorationof glass • A cost-effective alternative to tank coloration • Wide range of coloring possibilities • Flexibility

  4. Overview • More than just color... Xcite forehearth color (FHC) technology means… • 30 years of experience in FH color • development and troubleshooting • Full color-matching service • Rapid response • Full technological support • Colorant equipment design and supply • Computer modeling of cost savings

  5. Why Color in the Forehearth? • Flexibility • No need to color the entire tank • Perfect for short-run color campaigns • Can switch colors more easily than in the tank • Cheaper to switch dark colors back to flint • Allows cost-effective colored glass to be made near to the market • A viable alternative to consolidating color production in tanks which may be far from the market • Fits with current moves to rationalize and reduce the number of glass plants and tanks • Small and large forehearth applications;k16-k48 fh’s

  6. Why Color in the Forehearth? • Increase productivity • Reduced downtime during color changes • Less production losses • Color changeover times reduced from days to hours • Can continue to run flint on other lines while producing color • Faster customer response time • Lower total coloring costs/ton

  7. Why Color in the Forehearth? • Reduce inventory costs • Shorter campaigns mean less cash tied up in inventory • Lower warehousing costs • Lower energy consumption • Benefits of making base glass in high volumes can be maintained • No need to move colors production to less efficient, higher-cost small tanks

  8. Why Color in the Forehearth? • Reduce contamination potential • No color in the batch preparation facility • Reduce shipping costs • Can keep color production close to the market • Marketing support • Short color campaign potential gives opportunity to test market new products without incurring major costs of tank color

  9. Why Color in the Forehearth? • Conversion of tank colors • Opportunities to color more than simply flint • Reduce total number of tanks by converting one tank color to another normally produced in tank • Dead-leaf green to amber • Light amber to dark amber • Amber to black • Dead-leaf to antique green • Reduced Bordeaux to champagne green • UVA flint

  10. Markets & Applications • Cosmetic bottles • The original FHC application, fueled by this segment’s desire to produce small runs of specialized colors; still a growing market • Ralph Lauren Polo, Polo Sport, Davidoff, Avon, Nivea, CK, Gillette… • Emerald green, cobalt blue, copper blues, pink,amethyst, violet, black…

  11. Markets & Applications • Beverage containers • Soft drinks…Georgia Green Coke • Wines and spirits…champagne, Bordeaux, Bacardi, whiskey • Mineral waters…Clearly Canadian • Emerald green, dead-leaf green, cobalt and copper blues, olive, amethyst, black…

  12. Markets & Applications • Tableware • Tumblers • Cookware • Stemware • Art ware and giftware • Pressed-ware and blown-ware • Soda-lime and crystal • Green, black, yellow, pink, blue, amethyst...

  13. Markets & Applications • Flat Glass • Rolled patterned glass (RPG) • Extremely flexible, cost-effective application for FHC technology, increasing in popularity • Especially popular in Middle East, South America, Asia • Wired and non-wired applications • Large volumes: pull rates 100 to a potential of 200 tons per day • Glass building blocks • As with RPG, very cost effective compared to tank color • Popular colors: bronze, blue, green, amethyst, brown

  14. Forehearth Colorant Design Service • Close cooperation with forehearth engineers on preferred design • Colorant weighing, delivery and stirrer equipment design and layout • Full equipment package supplied • On-site commissioning of the coloring package in full cooperation with the forehearth engineers • Full color matching service • New color development and troubleshooting

  15. Products • Ferro invented and patented forehearth color concentrates (FHCC) • FHCC means higher color loading, lower % feed rates, high chrome green shades with better glass quality not possible with colored frits • Almost all colors are possible by forehearth coloring • Product can be color matched as frit or FHCC • For high tonnage pulls - e.g., containers and RPG-FHCC is generally the product form of choice • In some forehearth situations - e.g. short channel length - frits can be the preferred choice

  16. Example Products

  17. Equipment Package • Loading/weigh system including weigh hopper, scale feed and control system • Delivery system including vibratory conveyor and feed tube • Stirrer mechanism and speed controls, to ensure good color blending in the molten glass, giving homogenous color with good glass quality

  18. Critical Variables • Weigh system design: gravimetric preferred • Channel dimensions and shape, glass depth • Length of preheat, melting and stirrer zones - melt time, stirring time • Base glass analysis • Pull rate • Feed rate, typically 0.1 to 3% for FHCC, depending on product • Glass temperatures and control in the 3 zones: c. 1300-1220 o C • Number, position, speed, direction and design of stirrers • Feed point for FHC • FHC product design and formulation • Melt zone forehearth atmosphere and glass redox state

  19. FHC Proposal: What do we need? • New or existing forehearth to be used? • Layout and dimensions of existing forehearth and space available for possible forehearth modifications • Colors required • Tonnage pull rates required • Glass composition and cullet sample • Glass depth and temperature in the 3 FHC zones -preheat, melt and stirrer zones • End market segment

  20. FHC Proposal: What do we offer? • Color-matched patties in customer’s own glass • Forehearth evaluation and full design proposal, in conjunction with the forehearth build engineers • Ferro FHC equipment package and quotations • Recommendations on stirrer profiles and set-up • Recommendations on temperature/atmosphere • On-site commissioning support • After-sales service and local sales support

  21. Global Service • Manufacturing plants in USA, Europe • For sales and service, please contact the nearest Ferro office or agent in your region:Europe: France, Italy, Portugal, Holland, U.K., Czech RepublicAsia: Australia, India, Korea, Japan, Thailand, Hong Kong, ChinaNAFTA: USA, MexicoSouth America: Brasil