The Problem

Libbey Glass is the leading producer of high quality, machine made glass tableware in North America. A major furnace rebuild included a new batch charging system and replacement of the glass batch storage bin. Quality problems began after completion of this rebuild. The plant experienced several occurrences of glass quality deterioration that were traced back to relatively minor batch plant downtime events. The glass quality issues of cord, seeds and blisters (gas bubbles), and composition shifts appeared to be classic examples of batch segregation. On several occasions, the magnitude of the upsets were great enough to cause total production loss.

Jenike & Johanson's Solution

A BINSERT® hopper retrofit was recommended to convert the existing batch bin to mass flow and to control segregation. We developed the BINSERT® system to control and expand flow patterns in bins by using a mass flow hopper-within-a-hopper.

We also provided the equipment necessary for the retrofit. This consisted of a replacement lower hopper with an inner cone, support beams, and a liner for the portion of the upper hopper that was to remain. The retrofit was designed specifically for Libbey's installation and for the material being handled. We then provided assistance to the installation contractor to ensure that the job was completed correctly.

The Result

As a result of the changes made to the batch storage and delivery systems, the quality problems that had been plaguing the plant since the last rebuild have been eliminated. "Since the modifications have been implemented, there have been no negative impacts to glass quality on the numerous occasions of batch plant downtime" stated Mr. Dan Cetnar, Furnace Engineer at Libbey.

Another benefit realized after the retrofit was an increased live storage capacity. According to Mr. Cetnar, "Modification of the batch bin and the batch feed system resulted in a dramatic increase in the effective storage capacity, defined as usable, non-segregated batch."

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