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.
3. Real-Time Process Control (rMPC)
CelSian’s real-time monitoring system (rMPC) continuously tracks furnace operations, providing instant adjustments to optimize performance. By minimizing energy fluctuations and improving temperature control, manufacturers can reduce costs and extend equipment lifespan.
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.
Today, the U.S. Department of Energy (DOE) Office of Clean Energy Demonstrations (OCED) announced up to $6 billion in funding to decarbonize energy-intensive industries. Proposals from GMIC members Gallo Glass, Libbey Glass, and O-I Glass were among 33 projects selected for award negotiation. Multiple industries were represented in the announcement, including chemicals and refining, concrete, iron and steel, and aluminum and metals. The funding represents the largest investment in industrial decarbonization in U.S. history.
The DOE announcement detailed the three glass projects:
Gallo Glass, Hybrid Electric Glass Furnace Project: to install a demonstration hybrid electric furnace to reduce natural gas use by 70% and increase recycled content by 30% in its glass bottle production process. Gallo will leverage renewable energy provided by the local utility and anticipates selling low-carbon glass bottles as a premium option, contributing to the decarbonization of a large portion of glass for California’s wine and spirits industry.
Libbey Glass, Flexible Fuel Electric Hybrid Glass Furnace Demonstration Project: to replace four regenerative furnaces with two larger hybrid electric furnaces to reduce an estimated 60% of carbon dioxide emissions at Libbey’s facility in Toledo, Ohio. The hybrid furnaces combine the benefits of oxygen fuel with electric melting, replacing up to 80% of the melting energy with renewable-sourced electricity. Because glass tableware have some of the highest glass product standards, this project will demonstrate the viability of electrification and alternative fuel use for the entire glass industry.
O-I Glass, Glass Furnace Decarbonization Technology Project: to rebuild four furnaces across three of its facilities in California, Ohio, and Virginia to reduce scope one carbon dioxide emissions by an estimated 48,000 metric tons per year, an average of 40% reduction of scope one emissions across the four furnaces and their corresponding production lines. O-I plans to combine five cutting-edge furnace technologies on each furnace, demonstrating the functionality of combining multiple technologies across different glass colors and container types.
Funding for the program is provided primarily through the Inflation Reduction Act, as well as the Bipartisan Infrastructure Law.
The Glass Manufacturing Industry Council (GMIC) is pleased to announce that it has been selected by the U.S. Department of Energy to receive $3 million in funding to research advanced electric melting in glass manufacturing. The research is intended to reduce greenhouse gas emissions and help move the nation toward a net-zero economy.
The GMIC project was one of 49 selected, totaling $171 million in federal funding. Marie Kistler, GMIC President and Market Manager in Air Products’ Americas Strategic Marketing and Development organizaton, said “The submission and selection of the GMIC-led application for DOE funding is a great step forward for the industry. The efforts of GMIC members and partners have led to increased recognition of the glass industry’s important role in decarbonizing America’s industrial sector and the project results will benefit glass producers across multiple sectors.”
Partners on the project team are the Pacific Northwest National Lab (PNNL) in Richland, Washington; RoMan Manufacturing in Wyoming, Michigan; Toledo Engineering Company (TECO), and CelSian, both in Toledo, Ohio. With two recipients based in Northwest Ohio, Congresswoman Marcy Kaptur (OH-09) said, “As a region with a rich history in glass production, it is encouraging to see this $3 million federal award from the Department of Energy come back to the Glass City and Northwest Ohio. This partnership between the Glass Manufacturing Industry Council and its partners and the Department of Energy is a major step forward for glass production that moves us toward further decarbonization and a sustainable future. Glass and derivative industries remain vital for Northwest Ohio. I am pleased to assist in efforts to help keep our region competitive and at the forefront of glass manufacturing for generations to come.”
The project team will bring together extensive expertise in glass manufacturing, electric melting, lab-scale experimentation, computer modeling, and engineering solutions. Scott Cooper, Technical Director USA of CelSian, and principal investigator on the project, said “Electric melting has been successfully used at a commercial scale to make high-quality, industrial glass. However, some challenges have prevented its widespread adoption in higher-volume applications like container and flat glass production. Our project aims to address these challenges, advance electric melting technology for sustainable glass production, and provide viable options for the glass industry’s journey toward a lower-carbon future.”
Results of the anticipated three-year project will be shared in publications, community outreach efforts, and at the annual Glass Problems Conference, organized by GMIC.
For more information about the project partners, please visit their respective websites.
Marie Kistler, Market Manager in Air Products’ Americas Strategic Marketing and Development organization, started her term as GMIC President on January 1. Marie’s focus is on market dynamics and solutions for energy-intensive industries, such as Glass and Steel, where industrial gas products and technologies play a significant role in the energy transition. She especially enjoys collaborating with trade associations and their manufacturing and supplier members to advance the industry and solve common problems.
Looking ahead to 2024, Marie said, “I am honored to serve as GMIC President this year and I look forward to working together with the dedicated and dynamic team of GMIC staff and member representatives. I am excited to build on the framework and goals established in our new Strategic Plan aimed at increasing member value and amplifying the voice of the glass industry through advocacy, education, and research.”
Marie has a degree in Materials Science and Engineering from Carnegie Mellon University and has been with Air Products for over 35 years, including roles in Materials Engineering, Contract Research and Applied R&D.
Completing this year’s GMIC Executive Committee are Vice President Stanley F. Rutkowski, RoMan Manufacturing; Treasurer Benjamin Prothman, Acuity Brands; and Scott Cooper, CelSian Glass.
A new video, “The Age of Glass,” showcases activities from around the world that were developed in support of the 2022 United Nations International Year of Glass. The video is available at YouTube and includes events from last December’s Debriefing Session in New York at the UN Headquarters, which GMIC supported. Take a look back at this incredible year of glass events.
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