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

Xcite FHC TechnologyXcite FHC Technology

Ferro CorporationFerro Corporation

Worldwide GlassWorldwide Glass

Coloring Solutions for GlassColoring Solutions for Glass

Ferro CorporationFerro Corporation

Worldwide GlassWorldwide Glass

Coloring Solutions for GlassColoring Solutions for Glass

What is FHC Technology?What is FHC Technology? Introduction, melting and dispersion of colorants in Introduction, melting and dispersion of colorants in

the forehearth channel instead of the glass tankthe forehearth channel instead of the glass tank

Allows one or more forming machines to produce Allows one or more forming machines to produce individual colors without a full tank changeoverindividual colors without a full tank changeover

So, a flexible color operation can be created without So, a flexible color operation can be created without sacrificing the economies of large scale tank sacrificing the economies of large scale tank productionproduction

Almost all tank colors can be made also by FHCAlmost all tank colors can be made also by FHC

Xcite FHC TechnologyXcite FHC Technology

Delivers……..Delivers…….. An alternative technology for colorationAn alternative technology for coloration

of glassof glass A cost-effective alternative to tank colorationA cost-effective alternative to tank coloration Wide range of coloring possibilitiesWide range of coloring possibilities FlexibilityFlexibility

OverviewOverview More than just color...More than just color...

Xcite forehearth color (FHC) technology Xcite forehearth color (FHC) technology means…means…

30 years of experience in FH color30 years of experience in FH color development and troubleshootingdevelopment and troubleshooting Full color-matching serviceFull color-matching service Rapid responseRapid response Full technological supportFull technological support Colorant equipment design and supplyColorant equipment design and supply Computer modeling of cost savingsComputer modeling of cost savings

Why Color in the Why Color in the Forehearth?Forehearth?

FlexibilityFlexibility No need to color the entire tank No need to color the entire tank Perfect for short-run color campaignsPerfect for short-run color campaigns Can switch colors more easily than in the tankCan switch colors more easily than in the tank Cheaper to switch dark colors back to flintCheaper to switch dark colors back to flint Allows cost-effective colored glass to be made near to the Allows cost-effective colored glass to be made near to the

marketmarket A viable alternative to consolidating color production in A viable alternative to consolidating color production in

tanks which may be far from the markettanks which may be far from the market Fits with current moves to rationalize and reduce the Fits with current moves to rationalize and reduce the

number of glass plants and tanks number of glass plants and tanks Small and large forehearth applications;k16-k48 fh’sSmall and large forehearth applications;k16-k48 fh’s

Why Color in the Why Color in the Forehearth?Forehearth?

Increase productivityIncrease productivity Reduced downtime during color changesReduced downtime during color changes Less production lossesLess production losses Color changeover times reduced from Color changeover times reduced from

days to hoursdays to hours Can continue to run flint on other lines Can continue to run flint on other lines

while producing colorwhile producing color Faster customer response timeFaster customer response time Lower total coloring costs/tonLower total coloring costs/ton

Why Color in the Why Color in the Forehearth?Forehearth?

Reduce inventory costsReduce inventory costs– Shorter campaigns mean less cash tied Shorter campaigns mean less cash tied

up in inventoryup in inventory– Lower warehousing costsLower warehousing costs

Lower energy consumptionLower energy consumption– Benefits of making base glass in high Benefits of making base glass in high

volumes can be maintainedvolumes can be maintained– No need to move colors production to No need to move colors production to

less efficient, higher-cost small tanksless efficient, higher-cost small tanks

Why Color in the Why Color in the Forehearth?Forehearth?

Reduce contamination potentialReduce contamination potential– No color in the batch preparation facilityNo color in the batch preparation facility

Reduce shipping costsReduce shipping costs– Can keep color production close to the Can keep color production close to the

marketmarket Marketing supportMarketing support

– Short color campaign potential gives Short color campaign potential gives opportunity to test market new products opportunity to test market new products without incurring major costs of tank colorwithout incurring major costs of tank color

Why Color in the Why Color in the Forehearth?Forehearth?

Conversion of tank colorsConversion of tank colors– Opportunities to color more than simply flintOpportunities to color more than simply flint– Reduce total number of tanks by converting one Reduce total number of tanks by converting one

tank color to another normally produced in tanktank color to another normally produced in tank– Dead-leaf green to amberDead-leaf green to amber– Light amber to dark amberLight amber to dark amber– Amber to blackAmber to black– Dead-leaf to antique greenDead-leaf to antique green– Reduced Bordeaux to champagne greenReduced Bordeaux to champagne green– UVA flintUVA flint

Markets & ApplicationsMarkets & Applications

Cosmetic bottlesCosmetic bottles

– The original FHC application, fueled by this The original FHC application, fueled by this segment’s desire to produce small runs of segment’s desire to produce small runs of specialized colors; still a growing marketspecialized colors; still a growing market

– Ralph Lauren Polo, Polo Sport, Davidoff, Ralph Lauren Polo, Polo Sport, Davidoff, Avon, Nivea, CK, Gillette…Avon, Nivea, CK, Gillette…

– Emerald green, cobalt blue, copper blues, Emerald green, cobalt blue, copper blues, pink,pink,amethyst, violet, black…amethyst, violet, black…

Markets & ApplicationsMarkets & Applications

Beverage containersBeverage containers

– Soft drinks…Georgia Green CokeSoft drinks…Georgia Green Coke– Wines and spirits…champagne, Wines and spirits…champagne,

Bordeaux, Bacardi, whiskeyBordeaux, Bacardi, whiskey– Mineral waters…Clearly CanadianMineral waters…Clearly Canadian– Emerald green, dead-leaf green, cobalt Emerald green, dead-leaf green, cobalt

and copper blues, olive, amethyst, and copper blues, olive, amethyst, black…black…

Markets & ApplicationsMarkets & Applications

TablewareTableware

– TumblersTumblers– CookwareCookware– StemwareStemware– Art ware and giftwareArt ware and giftware– Pressed-ware and blown-warePressed-ware and blown-ware– Soda-lime and crystalSoda-lime and crystal– Green, black, yellow, pink, blue, amethyst...Green, black, yellow, pink, blue, amethyst...

Markets & ApplicationsMarkets & Applications

Flat GlassFlat Glass– Rolled patterned glass (RPG)Rolled patterned glass (RPG)

Extremely flexible, cost-effective application for FHC Extremely flexible, cost-effective application for FHC technology, increasing in popularitytechnology, increasing in popularity

Especially popular in Middle East, South America, AsiaEspecially popular in Middle East, South America, Asia Wired and non-wired applicationsWired and non-wired applications Large volumes: pull rates 100 to a potential of 200 tons Large volumes: pull rates 100 to a potential of 200 tons

per dayper day

– Glass building blocksGlass building blocks As with RPG, very cost effective compared to tank colorAs with RPG, very cost effective compared to tank color

– Popular colors: bronze, blue, green, amethyst, brownPopular colors: bronze, blue, green, amethyst, brown

Forehearth Colorant Design Forehearth Colorant Design ServiceService

Close cooperation with forehearth engineers on Close cooperation with forehearth engineers on preferred designpreferred design

Colorant weighing, delivery and stirrer Colorant weighing, delivery and stirrer equipment design and layoutequipment design and layout

Full equipment package suppliedFull equipment package supplied On-site commissioning of the coloring package On-site commissioning of the coloring package

in full cooperation with the forehearth engineersin full cooperation with the forehearth engineers Full color matching service Full color matching service New color development and troubleshootingNew color development and troubleshooting

ProductsProducts Ferro invented and patented forehearth color Ferro invented and patented forehearth color

concentrates (FHCC)concentrates (FHCC) FHCC means higher color loading, lower % feed FHCC means higher color loading, lower % feed

rates, high chrome green shades with better glass rates, high chrome green shades with better glass quality not possible with colored fritsquality not possible with colored frits

Almost all colors are possible by forehearth coloringAlmost all colors are possible by forehearth coloring Product can be color matched as frit or FHCCProduct can be color matched as frit or FHCC For high tonnage pulls - e.g., containers and RPG-For high tonnage pulls - e.g., containers and RPG-

FHCC is generally the product form of choiceFHCC is generally the product form of choice In some forehearth situations - e.g. short channel In some forehearth situations - e.g. short channel

length - frits can be the preferred choicelength - frits can be the preferred choice

Example ProductsExample Products

color oxides color loadings melt zone temps oC atmosphere issuesemerald Cr up to 15% 1230-1315 oxidizing very refractorybrown Ni up to 17% 1230-1315 ox.;1-3% refractorydeep blue copper up to 30% 1220-1260 oxidizing easy to melt

green blue Cu up to 30% max.1220 1-3% O2 redn.=color loss

amethyst Mn up to 32% low as possible oxidizing high T= " "

pink Se up to 1% 1220-1250 neutral ox base glassblack CrMn

greyCoNiyellowCrTi

Equipment PackageEquipment Package

Loading/weigh system including weigh hopper, Loading/weigh system including weigh hopper, scale feed and control systemscale feed and control system

Delivery system including vibratory conveyor Delivery system including vibratory conveyor and feed tubeand feed tube

Stirrer mechanism and speed controls, to Stirrer mechanism and speed controls, to ensure good color blending in the molten ensure good color blending in the molten glass, giving homogenous color with good glass, giving homogenous color with good glass qualityglass quality

Critical VariablesCritical Variables Weigh system design: gravimetric preferredWeigh system design: gravimetric preferred Channel dimensions and shape, glass depthChannel dimensions and shape, glass depth Length of preheat, melting and stirrer zones - melt time, Length of preheat, melting and stirrer zones - melt time,

stirring timestirring time Base glass analysisBase glass analysis Pull ratePull rate Feed rate, typically 0.1 to 3% for FHCC, depending on productFeed rate, typically 0.1 to 3% for FHCC, depending on product Glass temperatures and control in the 3 zones: c. 1300-1220 Glass temperatures and control in the 3 zones: c. 1300-1220 o o

CC Number, position, speed, direction and design of stirrersNumber, position, speed, direction and design of stirrers Feed point for FHCFeed point for FHC FHC product design and formulationFHC product design and formulation Melt zone forehearth atmosphere and glass redox stateMelt zone forehearth atmosphere and glass redox state

FHC Proposal: What do we FHC Proposal: What do we need?need?

New or existing forehearth to be used?New or existing forehearth to be used? Layout and dimensions of existing forehearth Layout and dimensions of existing forehearth

and space available for possible forehearth and space available for possible forehearth modificationsmodifications

Colors requiredColors required Tonnage pull rates requiredTonnage pull rates required Glass composition and cullet sampleGlass composition and cullet sample Glass depth and temperature in the 3 FHC Glass depth and temperature in the 3 FHC

zones -preheat, melt and stirrer zoneszones -preheat, melt and stirrer zones End market segmentEnd market segment

FHC Proposal: What do we FHC Proposal: What do we offer?offer?

Color-matched patties in customer’s own glassColor-matched patties in customer’s own glass Forehearth evaluation and full design proposal, Forehearth evaluation and full design proposal,

in conjunction with the forehearth build in conjunction with the forehearth build engineersengineers

Ferro FHC equipment package and quotationsFerro FHC equipment package and quotations Recommendations on stirrer profiles and set-upRecommendations on stirrer profiles and set-up Recommendations on temperature/atmosphereRecommendations on temperature/atmosphere On-site commissioning supportOn-site commissioning support After-sales service and local sales supportAfter-sales service and local sales support

Global ServiceGlobal Service

Manufacturing plants in USA, EuropeManufacturing plants in USA, Europe

For sales and service, please contact the For sales and service, please contact the nearest Ferro office or agent in your region:nearest Ferro office or agent in your region:

Europe:Europe: France, Italy, Portugal, Holland, U.K., France, Italy, Portugal, Holland, U.K., Czech RepublicCzech RepublicAsia:Asia: Australia, India, Korea, Japan, Thailand, Australia, India, Korea, Japan, Thailand, Hong Kong, ChinaHong Kong, ChinaNAFTA:NAFTA: USA, Mexico USA, MexicoSouth America:South America: Brasil Brasil