Beta Glass has achieved a record-breaking rebuild of its DF1 container glass furnace at its facility in Ughelli, Delta State, Nigeria.
The project was completed in 48 days, making it one of the fastest rebuilds in the global container glass industry.
The DF1 furnace rebuild encompassed a complete transformation of a 250 tpd, 70m2 container glass furnace.
Alexander Gendis, CEO of Beta Glass, said: “This world-leading DF1 furnace rebuild underscores Beta Glass's commitment to operational excellence, innovation, and sustainability.
“The DF1 rebuild not only strengthens our production capabilities but also reinforces our position as a leader in glass manufacturing across Africa.
“Our ability to deliver such a complex project safely on time, and to the highest standards, is a testament to the expertise and dedication of our team, partners, and suppliers.”
The DF1 furnace rebuild was led by Chief Operating Officer Jagdish Agarwal, whose leadership ensured a well-executed project marked by zero accidents.
A task force of 130 overseas contractors worked in co-ordinated 24-hour shifts, enabling rapid progress and precision.
The project also benefited from close collaboration with key global suppliers, including BDF, Furnotherm, All Glass, Bottero, MSK, and Tiama.
The DF1 rebuild will deliver benefits such as:
- Restored thermal performance: optimal temperature uniformity and efficiency.
- Energy savings: reduced gas and energy consumption by 7%.
- Enhanced reliability: minimised unplanned downtime and extended equipment lifespan by 11-17+ years.
- Quality assurance: improved product consistency with upgraded control and inspection systems.
- Modernisation: integration of smart SCADA technology for remote monitoring and advanced process control.
In addition to the scope of work outlined by Furnotherm, key highlights of the project include:
- Forming and inspection: overhaul of three IS forming machines, two new forming machines, and installation of an advanced cold end inspection system featuring Al and smart technology.
- Control system upgrade: new PLC, touchscreen HMI, temperature controllers, and safety relays.
- Production flexibility: integration of narrow neck press and blow (NNPB) and blow & blow technologies for lightweight food jars.
