Light Weighting

APEGG assist glass manufacturers to light weight containers, no matter the forming process and container type (jar or bottle). Starting with the container design, followed by mould design right through to the process parameters (forehearth and forming machine set-up) the Glass Experts team covers all.
Every glass container manufacturer has the opportunity to reduce glass weight either through optimisation of the process or redesign of the container, and thus improve the manufacturing costs. Less weight = less energy and raw material usage and more containers per ton of glass!
APEGG’s 7 steps to light weight:
1. Analysis: APEGG study the existing production, container design, and machine/process set-up. Discuss with the customer the current and future container requirements. After the studies a formal report with recommendation for light weighting is submitted.
2. Redesign: A concept proposal for the container (reduced weight) will be produced and agreed with the customer. During this process the brand image and functionality is considered by APEGG. The forming process most suitable for the new weight will be proposed during the design stage.
3. Cost/benefit: Light weighting does not always start with an immediate saving, sometimes, an initial investment is required. APEGG provide an analysis of cost vs profit, by analysing the different process points, such as, raw material batch, mould equipment, production/forming technology, and new packaging.
4. Container specification: With the cost analysis completed and the design concept agreed APEGG produce a complete container specification, including all relevant technical details.
5. Mould design: Following the agreed container specification APEGG will produce in house the required mould design, enabling the customer to purchase the necessary mould equipment. By redesigning existing containers, APEGG will strive to use if possible existing mould equipment.
6. Sampling: The trial or sampling is of paramount importance when introducing a new container design and this process must be followed all the way from the production, inspecting, and filling of the container.
7. First production: Once the container sampling proven to be successful, the first production run will follow. APEGG provide production assistance for the first run to ensure all process parameters are set at the best level and the mould equipment is performing as expected.
Concluding with a final report, the customer now has all what is required to successfully produce the container with less glass, whilst pulling the same amount of glass from the forehearth/furnace.
Important to note is, that in some cases it may be the production process which is not set up to achieve the optimum result and because of this glass is added unnecessarily. This is quite frequent for example in production of wide mouth jars. There is also light weighting by design process optimisation.
APEGG provide the right guidance for each individual glass manufacturer or brand owner.