Worldwide, glass manufacturing is a booming industry that asks manufacturers to produce a quality product but also reduce waste. This begs the question: How can we dramatically reduce the glass industry’s environmental impact without sacrificing its indispensable products? One promising answer is through the strategic use of artificial intelligence (AI). By leveraging data-driven insights and machine learning, AI is enabling glass manufacturers to optimize their processes in ways that cut emissions, save energy, reduce waste, and boost recycling.
How AI Is Supporting Sustainability Goals in the Glass Industry
AI technologies are helping glass manufacturers meet ambitious sustainability objectives:
Lowering emissions: AI process controls optimize furnace efficiency to cut CO₂ output.
Improving energy efficiency: AI adjusts equipment parameters to minimize energy use.
Reducing waste: Predictive maintenance and AI quality control limit scrap.
Increasing recycling: Smart sorting systems powered by AI boost cullet recovery.
Let’s take a closer look at each of these contributions.
Optimizing Energy and Emissions with AI
Furnaces are energy-intensive and a major source of CO₂. AI now plays a key role in optimizing these systems. By analyzing live data on temperature, fuel flow, and oxygen levels, AI fine-tunes the process in real time.
For instance, O-I Glass installed an AI-powered energy management system at its UK plant. Paired with battery storage, the AI determines when to charge or discharge to reduce demand on the grid. This system is projected to save 240 tons of CO₂ annually at that facility.
Beyond energy storage, AI-based furnace control systems constantly adjust settings to burn more cleanly and efficiently, without compromising product quality. Predictive analytics help forecast when components will degrade, allowing proactive maintenance and preventing fuel waste.
Improving Quality and Reducing Waste
AI improves yield by catching problems early. Machine vision systems inspect for bubbles, scratches, or warping and adjust production conditions before waste builds up. One case study showed how AI reduced cleaning time of forming molds from 5 hours to just 2 seconds, resulting in huge raw material and energy savings.
Causal AI tools can identify subtle process variations that lead to defects. When combined with predictive maintenance, these tools ensure consistent quality with minimal downtime. This leads to less scrap, fewer energy-wasting restarts, and better use of raw materials.
Boosting Circularity Through Smart Recycling
Glass is 100% recyclable, but sorting cullet efficiently is a major challenge. AI-enabled optical sorters now recognize glass by color, shape, and composition, separating contaminants and improving recovery.
By increasing cullet usage, glassmakers lower the need for virgin raw materials and cut energy consumption in melting. Every 10% increase in cullet can lead to about 3% energy savings and 7% fewer emissions.
Where the Industry Is Headed
At GMIC, we support our members in applying technologies like AI to meet environmental and operational goals. As more plants adopt smart manufacturing systems, we’re seeing:
Better data collection and sharing across plants
Collaboration between OEMs, tech providers, and producers
Scaling of pilot AI programs to full production lines
AI isn’t replacing skilled operators—it’s augmenting their decision-making. From fine-tuning processes to improving sustainability metrics, AI is enabling a cleaner, more efficient future for glass manufacturing.
Conclusion
How AI Is Supporting Sustainability Goals in the Glass Industry comes down to its ability to drive efficiency at every stage: cleaner melting, better quality, smarter maintenance, and more recycling. These gains align with GMIC’s mission to promote sustainable innovation.
As we work toward a greener industry, AI is not just a buzzword—it’s a tool helping us make meaningful progress. The companies leading the way are proving that glass can be both high-performance and low-impact.
A recent McKinsey & Co. survey of U.S. consumers reinforces what the glass industry has long known: recyclability is central to how Americans define sustainable packaging—and glass leads the way. Among all packaging materials, glass was ranked as the most sustainable, followed by paper and metal. These results reflect the high recycling rates and recycled content associated with glass, as highlighted in the full McKinsey report.
While price, convenience, and quality remain top priorities for shoppers, the survey found that 77% of Americans consider recyclability to be “extremely” or “very” important when evaluating packaging. Consumers also placed responsibility for packaging sustainability squarely on brand owners and packaging producers, not retailers or individuals—a significant insight from the McKinsey analysis. For glass manufacturers and their partners, this reinforces the competitive and ethical value of investing in truly recyclable materials.
The report urges businesses to design packaging that meets a full spectrum of consumer expectations—balancing cost, safety, and performance with environmental responsibility. With non-recyclable multimaterial packaging presenting ongoing challenges, glass stands out for its simplicity, recyclability, and durability. For brands looking to lead on sustainability, embracing glass is both a smart and strategic move in today’s evolving consumer landscape.
Verescence, the global leader in glass bottles for the Perfumery and Cosmetics industries, has announced the arrival of new shareholders: Movendo Capital and Draycott. These two family-owned investment firms bring deep experience and a shared commitment to long-term value creation. The move is expected to strengthen Verescence’s global operations, which span 4 glass production sites and 5 finishing sites across Europe, North America, and Asia, with a workforce of 2,500 employees.
The leadership at Verescence, including President Thomas Riou, expressed enthusiasm for the new partnership, citing alignment with the company’s strategic roadmap and sustainability efforts. “We are pleased to welcome new shareholders who support our strategy, investment plans, and decarbonization roadmap,” said Riou. With over 130 years of glassmaking expertise and an annual output of 600 million bottles, Verescence continues to be a preferred partner for top beauty brands worldwide.
Representatives from both investment firms echoed the optimism, highlighting Verescence’s industry leadership and potential for sustainable growth. João Coelho Borges of Draycott and Pedro Pereira Gonçalves of Movendo emphasized their intent to collaborate closely with Verescence’s management to drive innovation and stakeholder value. “Verescence fits perfectly with our long-term investment vision,” added Pereira Gonçalves. “Together, we aim to scale new heights while maintaining a strong focus on sustainability and operational excellence.”
About Movendo Movendo Capital is an investment company based in the Netherlands and operating in Europe and United States. The company is focused on managing investments in growing companies that operate in the food value chain and branded consumer goods, with an innovative business approach, which are located in Europe and the United States. Movendo Capital is owned by Sociedade Francisco Manuel dos Santos, a fourth-generation family holding that is owned by Portuguese family shareholders with a range of investments in different areas, namely, distribution, manufacturing, agrifood, specialized retail, citizenship, and environment.
About Draycott Draycott is an emerging Portugal-based investment management firm, founded by a senior team with more than 20 years of experience in private investments and a track record of investing more than EUR 2 billion in equity across multiple sectors. Draycott operates across buyouts, real estate, and venture capital, actively building a leading position in private equity, focusing on disciplined investments and value creation. Among its investment vehicles, Draycott Fund I serves as the family office of its founding partner and will be the vehicle participating in the acquisition of Verescence. This investment
The U.S. Department of Energy’s (DOE) Better Plants program has emerged as a significant initiative, encouraging industries nationwide to reduce energy intensity, enhance sustainability, and boost competitiveness. This article explores the Better Plants program’s impact within the glass industry, highlighting active efforts by several prominent Glass Manufacturing Industry Council (GMIC) members.
What is the DOE Better Plants Program?
The Better Plants Program works with leading U.S. manufacturers and wastewater treatment agencies to set ambitious energy, water, waste, and/or emissions reduction goals.
The Better Plants Program offers:
-Expert technical assistance and training on energy efficiency
-Peer-to-peer learning and networking opportunities
-Access to Innovation at the National Labs
-National recognition for achievements
By partnering with industry, the Better Plants program aims to help manufacturers boost efficiency, increase resilience, and strengthen economic competitiveness
The Better Plants program supports over 270 partners –accounting for 14% of the U.S. manufacturing footprint
DOE is committed to continually learning from our Better Plants partners, who help to shape and inform strategic planning for the program.
GMIC Members Involved
Several GMIC members actively participate in the Better Plants program, exemplifying commitment and leadership in sustainability:
Acuity Brands
Acuity Brands is recognized for its extensive work in energy-efficient lighting and building management solutions. By actively engaging with the Better Plants program, Acuity Brands aims to significantly reduce energy consumption across its manufacturing operations, setting a powerful example for industry peers.
CertainTeed (Saint-Gobain)
CertainTeed, a subsidiary of Saint-Gobain, has long been at the forefront of sustainability and energy efficiency. Through their participation in the Better Plants program, they focus on optimizing manufacturing processes, reducing environmental impact, and promoting sustainable building solutions.
Saint-Gobain Corporation received a 2025 Better Practice Award from U.S. Department of Energy during the Better Buildings, Better Plants Summit. Read More Here.
Owens Corning
Owens Corning consistently integrates sustainability into its operations. Their involvement with the Better Plants program reinforces their dedication to reducing energy use and greenhouse gas emissions. By leveraging DOE resources, Owens Corning continues to achieve substantial efficiency gains.
Vitro Architectural Glass
Vitro Architectural Glass participates actively in the Better Plants program, demonstrating strong leadership in environmental stewardship. They focus on enhancing the energy efficiency of their manufacturing processes and consistently develop innovative products that support sustainable construction.
Imerys and Siemens: Associate Member Contributions
GMIC associate members Imerys and Siemens also contribute significantly to the industry’s energy efficiency goals through their participation in Better Plants. Imerys, a global leader in mineral-based specialty solutions, works rigorously to improve sustainability in their supply chain and manufacturing practices. Siemens, renowned for innovative technology solutions, collaborates closely with the DOE to enhance energy efficiency through advanced digital and automation solutions.
Broad Industry Benefits
The collaborative nature of the Better Plants program provides manufacturers with unique opportunities to share best practices and innovative approaches. By collectively reducing energy intensity, participants significantly lower operational costs, reduce environmental impacts, and position their businesses as sustainability leaders.
Looking Ahead: Industry-wide Opportunities
Even organizations outside the program can benefit from the pioneering efforts of Better Plants participants. Industry-wide adoption of demonstrated best practices can elevate sustainability across the glass manufacturing sector, reinforcing the industry’s role in a more sustainable, energy-efficient future.
Conclusion
The DOE Better Plants Program exemplifies effective collaboration between government and industry, driving substantial energy efficiency improvements. GMIC proudly highlights our members’ active participation and achievements, underscoring their crucial roles in advancing industry-wide sustainability goals.
Energy costs can account for up to 14% of total glass production expenses? In an industry where margins are tight, optimizing energy efficiency isn’t just beneficial—it’s essential. The U.S. glass industry faces ongoing challenges in reducing energy consumption while maintaining production quality. This blog explores how CelSian’s Energy-Saving Technologies are transforming glass furnace operations, aligning seamlessly with the U.S. Department of Energy’s (DOE) initiatives to promote sustainability and efficiency.
Understanding the Energy Challenges in Glass Manufacturing
Glass production is highly energy-intensive, requiring extreme heat to melt raw materials into a usable form. The industry’s reliance on high-temperature furnaces leads to substantial energy costs and environmental impact. In response, the DOE has introduced programs to support energy-efficient technologies and workforce training, helping manufacturers lower emissions while improving productivity.
At the forefront of energy optimization in glass manufacturing is CelSian, a company dedicated to providing cutting-edge solutions for furnace operations. Their comprehensive approach includes advanced software, real-time monitoring systems, and workforce training to help manufacturers achieve greater efficiency.
1. Advanced Furnace Modeling (GTM-X)
CelSian’s GTM-X software allows glass manufacturers to simulate furnace operations and identify energy inefficiencies before making costly changes. This predictive modeling tool optimizes combustion, reduces energy waste, and enhances furnace longevity.
2. Specialized Training Programs
Recognizing that technology is only as effective as the people using it, CelSian offers industry-leading training. Their programs, such as the General Glass Technology Training, have educated thousands of professionals in best practices for energy-efficient glass production.
CelSian’s Role in DOE’s ISEED Initiative
The U.S. Department of Energy (DOE) has launched the Industrial Sustainability, Energy Efficiency, and Decarbonization (ISEED) Collaborative, a $3.6 million initiative aimed at improving industrial energy efficiency. CelSian Glass USA was selected as one of only six organizations to participate.
Over the next two years, CelSian will receive DOE funding and technical support to develop and expand specialized training programs that focus on energy efficiency in glass-melting furnaces. These courses include:
Hands-On Hot Repair
Oxy-Fuel Furnace Operations
Sustainable Furnace Operations
These initiatives will not only improve energy efficiency but also create career pathways in the glass manufacturing sector, supporting workforce development across the U.S. By 2025, these programs will be integrated into a national training platform for the industry.
For more details, read the full Glass International articlehere.
Why This Matters for Glass Manufacturers
For glass manufacturers, adopting energy-efficient technologies is no longer optional—it’s a competitive necessity. By leveraging CelSian’s energy-saving technologies, companies can:
✔ Lower energy costs by optimizing furnace operations ✔ Reduce emissions and contribute to sustainability efforts ✔ Improve productivity with data-driven process control ✔ Stay ahead of regulatory changes related to industrial emissions
With DOE-backed initiatives supporting the shift toward energy efficiency, now is the time for manufacturers to integrate CelSian’s solutions into their operations.
Explore CelSian’s Cutting-Edge Solutions
CelSian continues to lead the industry with innovative technologies and training programs that drive efficiency in glass manufacturing. Learn more about their solutions here.
Last year, GMIC was awarded a three-year, $3 million grant from the Department of Energy to research advanced electric melting to decarbonize commercial glass. Each quarter, we’ll updatemembers on the research and the milestones achieved.
The objective of the project is to demonstrate melting processes which reduce scope-1 greenhouse gas emissions by 85+% for large volume, commercial glass production. The focus will be on overcoming three barriers which have hindered adoption of all-electric glass furnaces: ✔ Production of dark/reduced colored glasses (e.g. amber) ✔ Improve quality of clear glass ✔ Furnace lifetime
The project launched in the last quarter of 2024, and accomplishments last quarter included: ✔ Establishing the project lab and modeling capabilities ✔ Setting up the Cold-Top Melting Furnace ✔ Testing the pelletizing set up ✔ Completing the CFD grid of the Cold-Top furnace ✔ Establishing the future workflow plans
The Cold-Top furnace set up in the temporary space at University of Toledo
In addition, the team established base line recipes for the amber and flint tests. These recipes were chosen to represent real industrial glass melt formulas and be consistent across project members conducting tests in the CelSian lab, the PNNL lab, and through CFD modeling. Industrial-grade raw materials and post-consumer flint cullet were obtained from industrial steering committee partner Gallo Glass to maintain consistency with real-world industrial processes. Internal flint cullet was also obtained from a separate glass plant because of ease of acquisition.
For the quarter, five successful cold-top experiments were run on the Cold-Top furnace: o Container batch containing 30% post-consumer flint cullet at 2.0 ton/m 2 /day o Container batch containing 30% internal flint cullet at 2.0 ton/m 2 /day o Container batch containing 30% internal flint cullet at 1.75 ton/m 2 /day o Container batch containing 70% internal flint cullet at 2.0 ton/m 2 /day o 100% internal flint cullet at 2.0 ton/m 2 /day
The project partners are Celsian (lead investigator), RoMan Manufacturing, TECO, and the Pacific Northwest National Laboratory (PNNL).
Stanley Rutkowski, Senior Applications Engineer at RoMan Manufacturing, has begun his term as President of the Glass Manufacturing Industry Council (GMIC) for 2025. Stan is eager to advance key initiatives, including the Department of Energy grant, hosting October’s Glass Problems Conference in Toledo, and growing GMIC’s committees.
GMIC is on the move to a new office in Toledo, Ohio! Our new business address is:
3950 Sunforest Ct Suite 200, Office 209 Toledo OH, 43623
After many years of being co-located with the American Ceramic Society in Columbus, OH, our office was sublet, and we used the opportunity to rethink our footprint. After a thorough search in both Columbus and Toledo, we settled on a shared office location in the Glass City.
In this new year and new location, we look forward to advancing the glass industry and supporting the work of our members. Best wishes for happy and prosperous 2025!
The May 2024 edition of the ACerS Bulletin includes, “Empowering Sustainability: The US glass industry charged to break barriers for a greener future.” The article, by Scott Cooper, GMIC Past President and Technical Director USA for CelSian; and Kerry Ward, GMIC Executive Director, explores cutting-edge advancements in electric melting and how new technology can revolutionize glass manufacturing and increase energy efficiency.
The U.S. Department of Energy’s (DOE) Industrial Efficiency & Decarbonization Office (IEDO) is inviting stakeholders from across the glass manufacturing supply chain (e.g., glass manufacturers, equipment manufacturers, raw material providers, etc.) to participate in a workshop on glass decarbonization on May 16th and 17th, 2024 at the Hyatt Pittsburgh International Airport hotel in Pittsburgh, PA.
The goal of the workshop is to identify key challenges, priorities, and opportunities for decarbonization of the glass manufacturing sector. Emphasis will be placed on technical challenges, as well as applied research, development, and demonstration (RD&D) opportunities at low to mid technology readiness levels (TRLs). During the workshop, IEDO leadership will provide an overview of the office and share the vision, strategy, and available resources to support innovations to improve energy efficiency and reduce the carbon footprint across U.S. manufacturing operations. Through facilitated discussion, participants will help inform IEDO’s priorities and future plans in supporting decarbonization of the glass manufacturing sector.
This event is targeting participation from stakeholders with technical and/or practical expertise related to glass manufacturing, decarbonization technologies, and/or applied RD&D. The event has limited capacity and IEDO is requesting that no more than two representatives from each organization participate.
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