Life cycle analysis of container glass in india

1. 1
Presented at Greenco -CII
Arindom Chakraborty
Hindusthan National Glass & Ind. Ltd.
Member-AIGMF
June 21, 2017
Life Cycle Analysis
Container Glass Bottle

2. 2
Glass – what & why
Every ton of glass recycled saves 322 KwH of energy, 246 kg of CO2 & 1200 kg of virgin raw material
Helps in Savings on Waste collection, Transportation and Disposal costs
Product packaged in glass denotes premium quality
 Made from all natural and sustainable raw material - silica sand, soda-ash, lime stone etc.
 100% Recyclable and can be re-used more than 40 times
 Chemically inert and pure

3. 3
What the consumers say across the globe ….
Source : European Container Glass Federation (FEVE) Consumer Research
92% of consumers want safe drinking water and are
willing to pay more for a better packaging than Plastics
60% say they are willing to pay more for more
sustainable packaging as compared to plastics
72% say they want more environment friendly packaging 81% want industry to use more glass containers

4. 4
Why LCA of container glass
1. To evaluate the environmental profile of glass, determine improvement opportunities.
2. External communication of product environmental attributes for enhancing the green brand of
glass product amongst consumers and other stakeholders.
3. Independent Review by Panel of International Experts.
4. Comparison with alternative packaging materials such as PET, beverage carton, pouch, Al Can.
AIGMF
PE International /
Thinkstep

5. 5
Comprehensive Life Cycle study
7600 TPD of container glass industry covered
24 Sites visited by research team
72% Capacity using state of the art technology
40-250 Range of furnace size (TPD)
1st LCA study of an industry
association in India that is performed
and reviewed against ISO 14040/44
State-of-the-art LCA methodology as
applied by FEVE and GPI

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Cradle to Cradle
Cradle-to-Cradle is the
ultimate test in assessing
the environmental impact
of a product because it
ensures that all aspects of
a product’s life, end-of-life
and reincarnation are
accounted for.

7. 7Source: PE International Life Cycle Assessment (LCA) Study in India, 2011
Methodology
 LCA models are created using the GaBi 5 Software for life cycle engineering,
developed by PE International AG. GaBi database provides the life cycle inventory
data for several of the raw and process materials obtained from the upstream and
downstream system.
 For 180 ml packaging size of all packaging systems, various sensitivity analyses have
been performed in order to assess the influence of different parameters.
 3rd party critical review was carried out to assess
1. Methods are consistent with ISO 14040 and ISO 14044,
2. Methods used to carry out the LCA are scientifically and technically valid,
3. Data used are appropriate and reasonable in relation to the goal of the study,
4. The study report is transparent and consistent.
1. Mr. Matthias Fischer
Head of the Life Cycle Engineering
Department
Fraunhofer IBP and University of
Stuttgart, Germany
2. Mr. VS Mathur
General Manager (Quality and
Environmental)
Tata Chemicals Limited, Babrala, India

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Container glass – Carbon Footprint
Source: PE International Life Cycle Assessment (LCA) Study in India, 2011
LCA Study of Container Glass in India – Key Findings
16.6 18.9
13.6
1.25
1.55
1.09
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0
10
20
30
40
North America India (No Reuse) India (25% Reuse)
Primary Energy demand(MJ/kg of glass)
Global Warming Potential(kg CO2 Eq/kg of glass)
1. Indian glass manufacturing process is
highly energy efficient & adopts best
in the world technologies.
2. Increased usage of recycled glass
from 35% at present to 75% will
reduce carbon footprint by almost
40%. In Europe, most of countries
use from 80% - 90% of recycled glass.

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 In India, only glass is being reused.
 Very high landfill rate (80%) for
Aluminium, Liquid carton board & pouch.
 Significant open burning for used
materials in case of PET, Liquid carton &
pouch leading to environmental pollution
& is a serious health hazard.
0%
20%
40%
60%
80%
100%
32%
42%
80%
20%
38%
38%
20%
80%
80% 80%
20% 20% 20%
30%
Recycling Landfill Open burning Reuse
End of life for packaging mediums
Source: PE International Life Cycle Assessment (LCA) Study in India, 2011
LCA Study of Container Glass in India – Key Findings

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 Glass is by far the most eco-friendly
material while packaging is concerned
 Shelf-life of Food & Beverages
packaged in glass is longer than in
other packaging mediums
Glass vis-à-vis Plastic
Human Toxicity
Photochem. Ozone Creation
Terrestric Ecotoxicity
100
100
100
123
136
246
Plastic
Glass
Source: PE International Life Cycle Assessment (LCA) Study in India, 2011
LCA Study of Container Glass in India – Key Findings

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Effect of weight reduction & recycling on environmental profile of glass
Source: PE International Life Cycle Assessment (LCA) Study in India, 2011
LCA Study of Container Glass in India – Key Findings
Weight reduction
(-20%)
Acidification 18%
Eutrophication 17%
Global Warming 18%
Human Toxicity 15%
Terrestric Ecotoxicity 17%
Photochem. Ozone Creation 18%
Primary energy demand from ren. and
non ren. resources
16%
Recycling
(75%)
40%
37%
39%
15%
35%
43%
31%
Weight reduction
(-20%) & Recycling (75%)
45%
44%
50%
27%
52%
45%
41%
With increased recycling & reduced weight ,
environmental effects of glass can be reduced by 50%.

12. LCA Study on container glass in India – Recommendations
12
Glass manufacturers to lower environmental effects of glass to establish glass’ green edge over
other packaging mediums on human and environment impact parameters through………..
• Initiating weight
reduction of glass
by as much as 20%
through
deployment of
international
technologies like
Narrow Neck Press
& Blow (NNPB)
Light Weighting
• Converting from furnace
oil as fuel in furnaces to
natural gas to 50% from
present 30% by the next
three years. An
opportunity for earning
carbon credits to the tune
of 1.2 million for every 10
million tonnes of
production.
Energy
Optimisation
• Maximising cullet
recycling from
current all India
average of 35% to
50% with expected
reduction of carbon
footprint by 22%
Cullet Collection
Source: PE International Life Cycle Assessment (LCA) Study in India, 2011

13. Container glass – End of life
13Source: PE International Life Cycle Assessment (LCA) Study in India, 2011
(1) Closed-loop of glass packaging back to new packaging
(2) Recycling of glass packaging into non-packaging products or fiberglass
(3) Losses via aggressive landfill cover, incineration
End-of-life management scenarios
Benefits of Closed-loop Recycling
a) Substitution of primary batch materials by cullet.
b) Reduction of energy consumption in melting process due to cullet replacing raw materials.
c) Reduction of emissions in melting process:
i. Reduction of CO2 emissions in relation to the (reduced) consumption of raw materials and energy.
ii. Reduction of NOx, Dust and SOx emissions in proportional relation to the (reduced) energy input.

14. Glass Recycling – more the better
14
 Europe uses almost 70% recycled
glass on the average
 Only 40% glass is recycled in India &
rest goes into landfill
Source: European container glass federation (FEVE)
At 50% recycled glass in manufacturing,
Removes 2.2 million MT of CO2 emissions =
400,000 cars off the road each year.
Recycling rate ~90%

15. Way Ahead in India
15
Stakeholders Opportunity
FMCG companies
► Implement more renewable/ recycled material in their product.
► Implement recycling and reusing initiatives in order to increase the rates of recycling for their products.
Consumers
► Follow proper waste disposal practices.
► Demand that their products encompass a holistic value chain.
Policy makers
► Promote the informal sector to collect low value waste material.
► Propose legislation to propel green packaging.
Local municipalities
Develop controlled waste streams they own in order to ensure all waste is collected and not just those with
high market value.
Investors Direct investment to expand green packaging, formal waste management.
Packaging supplier Demonstrate commitment to sustainable packaging.

16. Recycling – what about these
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An airport in England collects recycled gum to help make tires, toys, and other products
Wine corks can be recycled into flooring tiles, insulation, automotive parts & sports equipment
Credit cards are chopped and melted into sheets of PVC
Used diaper - fibre and plastic to be recycled into products ranging from benches to railways sleepers

17. Is Recycling enough ??
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Not just Recycling…..
Reduce
Reuse Recover
Repair
Rethink
Rotate Replenish
Recover
Return Restore
Responsibility
Reinvent
Rethink

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