Digital Bottle

Encirc, part of Vidrala, an industrial company that manufactures and sells glass products for the food sector, was looking to improve its plant process control systems bringing more efficiencies and modern technologies to its production lines, including the first net-zero glass bottle production by 2027.

Ayesa collaborated with Encirc, a company that has a 40% market share with two plants in the UK (Northern Ireland, Cheshire) and one in Italy. The company is a division of Vidrala,  a leading global glass manufacturer and co-packer. Ayesa analysed data gathered via advanced sensor and traceability systems across its manufacturing operations, powered by AI analytics  Ayesa’s focus was on optimising the container glass furnace plant and associated production lines. As a result, the furnaces now operate with significantly reduced energy consumption while maintaining high-quality glass output. Furthermore, using this data has minimized defects and production rejects in the packaging and melting processes.This project illustrates how Artificial Intelligence (AI) is revolutionizing energy management and operational efficiency in the industrial sector.

This project has streamlined each manufacturing process, achieving notable energy savings of up to 9% in the glass furnaces at Encirc’s Elton plant, equating to over 61MWh/year and 2.2 million pounds. Additionally, it enhances process productivity by 2.5%, resulting in savings of 27MWh/year and £1 million annually. The overall estimated CO2 reduction amounts to 15,600 tons per year.

Moreover, the project optimizes process efficiency for operators while reducing the necessary operational safety margin, ensuring reliable furnace operation.