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Feature: Onward and upward

Despite the recent decision to end the Recycle More Glass scheme, Berryman Glass and long-time partner Rockware Glass are aiming to continue delivering real benefits across the whole glass recycling supply chain, ensuring that investment and effort go into increasing and improving the volume and quality of cullet required for glass container manufacturing.

It is hoped that the decision by Berryman to close its national Recycle More Glass operation in favour of more local contractors will establish continuity as well as enable Berryman to concentrate on its mainstream domestic kerbside and bring activities through local authorities and community groups, and on its growing cullet treatment operation.

Mike Keogh, Berryman general manager explains: “It is regrettable that we did not get the support from the on-trade that we expected to make Recycle More Glass a viable operation. But with the investments that we are making in new state-of-the-art cullet treatment plants and the growth particularly in kerbside schemes across the country, we want to concentrate all our efforts on helping our local authority customers meet their targets, as well as providing our long-term recycling partner Rockware Glass with the highest quality of cullet.”

Energy saving and emission abatement technology new to the UK both featured highly in the £25 million investment programme that is nearing completion at Rockware’s Knottingley factory. It forms part of an environmental package that includes new cullet treatment and enhancement capacity, and state-of-the-art particulate emissions abatement technology. Collectively, they enable the company to continue to make progress in meeting its sustainable development goals, for which it was granted the Queen’s Award for Enterprise in 2003.

When Rockware installed the world’s first servo- assisted Owens-Illinois 10-section quadruple gob machine and the UK’s highest productivity machine line for making glass bottles at its Knottingley beer bottle production plant, it also became the first UK glass manufacturer to install a very low emissions dust filter plant. The German-built filter plant system designed to a Rockware spec removes particulates from the chimney emissions by the injection of lime, which is constantly recycled, followed by the filtration of resulting dusts.

Engineering modifications enable the dust to be recycled back into the furnace, and the total system has proved so efficient that it is being installed on two more furnaces at Rockware this year.

“Our drive for continuous improvement in using more recycled glass from the waste stream, coupled with our search for best practice in meeting environmental obligations, imposes an immensely challenging task on our managers and engineers,” says Rockware’s chief executive David Currie.

An example of the companies’ commitment is the investment in a new cullet treatment plant, which has just opened alongside Rockware’s Wheatley factory in Doncaster. Modelled on a similar plant in nearby Knottingley, this advanced new facility will double the volume of high-quality cullet that Berryman is able to supply to Rockware.

Processing predominantly flint cullet, the plant will fill a much-needed gap in the market in line with demand. The plant also has the flexibility to switch to green and amber glass. With a capacity of 225,000 tonnes per annum, it doubles Rockware’s ability to process cullet. The investment is in line with Rockware’s vision to build th

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