Beta Glass bets on world-record DF1 furnace rebuild to drive efficiency gains
Beta Glass Plc has completed the rebuild of its DF1 container glass furnace at its Ughelli, Delta State plant in a record 48 days, a milestone the company says sets a new global benchmark in the glass container industry.
The project, which involved a complete transformation of a 250-ton, 70-square-metre furnace, is designed to increase production capacity, enhance product quality, and cut energy use by about seven percent. The rebuilt furnace integrates advanced automation and artificial intelligence systems to improve process control and inspection.
Alexander Gendis, chief executive officer of Beta Glass Plc, said the achievement underscores the company’s commitment to operational excellence and sustainability.
“This world-record DF1 furnace rebuild underscores Beta Glass’ commitment to operational excellence, innovation, and sustainability,” he said. “It not only strengthens our production capabilities but also reinforces our position as a leader in glass manufacturing across Africa.”
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Utility systems were overhauled with stainless steel water lines across 26 circuits, new air and gas pipelines, and fabricated ducts, nozzles, and fans serving five forehearths. Electrical upgrades included new MCC panels, cabling, and instrumentation, while the forming and inspection lines saw the overhaul of three IS forming machines, addition of two new machines, and installation of an AI-driven cold-end inspection system. Control systems were modernised with PLCs, touchscreen HMI units, temperature controllers, and safety relays.
The rebuild was led by chief operating officer Jagdish Agarwal and completed without a single accident, according to the company. About 130 overseas contractors worked in 24-hour shifts alongside local engineers, supported by key global suppliers including BDF, Furnotherm, All Glass, Bottero, and MSK Tiama.
Upgrades include new exhaust systems, combustion and cooling units, and an AI-enabled inspection line. The furnace also integrates narrow neck press and blow (NNPB) and blow-and-blow technologies, which allow for the production of lighter food jars and bottles.
Beta Glass said the new DF1 unit restores optimal thermal performance, improves efficiency, and extends furnace lifespan by as much as 17 years. The installation of smart SCADA technology now enables remote monitoring and advanced process control, reducing downtime and enhancing product consistency.
