Encirc and Glass Futures launch bio-fuel trial for “world’s most eco-friendly” glass bottle

09 Oct 2020 --- Encirc glass container manufacturer and Glass Futures industry research and technology organization are partnering on a landmark project to create “the world’s most sustainable glass bottle.” In 2021, Encirc’s Derrylin plant in Northern Ireland will pioneer bio-fuel on one of its furnaces, paving the way for an industry-wide reduction in carbon emissions.

Alongside this 30-day trial, Encirc will use up to 96 percent recycled glass to create the new bottles, further reducing the carbon footprint.

Bio-fuel is made from plant materials, offering a more environmentally sustainable fuel alternative to the fossil fuels traditionally used by the glass sector. Renewable bio-fuel is estimated to reduce carbon emissions by up to 90 percent compared to fossil fuels.

If successful, these low-carbon fuel technologies have the potential to remove up to 1.2 million tons of CO2 emissions per year by 2030, totaling more than 20 million tons by 2050, the partners indicate.

The trial comes as Ardagh research reveals 34 percent of households from over 2,100 people surveyed in the UK, Germany and Poland are recycling more glass packaging during the months of COVID-19 lockdown.Encirc will use up to 96% recycled glass to create the new bottles. According to Ardagh, 580 kg of CO₂ are saved per ton of glass recycled.

Project decarbonization
The UK trial, which is due to be completed in March 2021, is reportedly the world’s first and its results will feed into UK Government policy on decarbonization.

The trial forms part of the Department for Business, Energy and Industrial Strategy (BEIS) Energy Innovation Programme. Within this, non-profit Glass Futures is leading a £7.1 million (US$9.2 million) project to determine the most effective route to switch the glass sector to low carbon fuels.

“We will learn the operational and technical parameters for running glass melting facilities on bio-fuels to establish a new method of low-carbon manufacture for glass,” Aston Fuller, Glass Futures general manager, tells PackagingInsights.

A key focus for the bio-fuel project is reducing the sector’s carbon footprint and the impact of glass manufacturing in the UK, future-proofing an industry employing 23,000 people.

Hitting up hydrogen
Fuller explains hydrogen is tipped as a potential alternative low carbon fuel, in addition to bio-fuels.

“The entire supply chain shows interest in trials of low-carbon technology, helping to pull together major collaborations. These collaborations are the foundation of Glass Futures’ approach and we invite any interested supply chain partners to join us on this low carbon journey.”The UK trial is a world-first and the results will feed into UK Government decarbonization policy.

“We’re also looking at advancements in electric melting to truly discover the future of glass production,” continues Fiacre O’Donnell, director of sustainability at Vidrala, Encirc’s parent company.

“We’ve already seen a huge level of interest from beverage suppliers in attaining the ultra-low-CO2 containers we’ll be making during the trial.”

“Glass is already a wonder material in terms of sustainability, able to be recycled a limitless number of times, without losing any quality.”

“However, as with any manufacturing process, it is still an energy-intensive sector. By working with Glass Futures, we can help pioneer the development of a glass bottle, which will truly have no negative impact on the environment,” O’Donnell reiterates.

The project involves multiple industry partners and will include biofuel trials on a full-scale commercial line and a large lab scale hydrogen demonstration.

Lockdown inspired recycling hikes
According to metal and glass packaging supplier Ardagh, European households are embracing glass recycling during lockdown.Ardagh research reveals 34% of UK, German and Polish households recycled more glass during COVID-19 lockdown.

With the closure of bars and restaurants in the initial phase of lockdown, people consumed more foods and beverages packed in glass at home, leading to an increase in the volume of glass being recycled via domestic recycling streams.

The actual increase in glass recycling varied by country, with 40 percent of people in the UK and Poland, and 21 percent of people in Germany, indicating they were recycling more glass.

Glass recycling companies in the UK confirm they have seen a significant increase in household recycling rates since lockdown.

The research also shows that recycling methods vary due to differences in national collection infrastructures. In Germany and Poland, the most common way to recycle glass is via glass banks, with 86 percent of households in Germany and 72 percent in Poland saying they “always” or “often” use glass banks to recycle glass.

For every ton of glass recycled, the industry saves 580 kg of CO₂, enough energy to charge 74,000 smartphones, Ardagh says.

By Joshua Poole