Beta Glass, the leading manufacturer of glass packaging solutions in West and Central Africa, is proud to announce the successful world-leading rebuild of its DF1 container glass furnace at the company’s state-of-the-art manufacturing facility in Ughelli, Delta state, Nigeria. The comprehensive project is set to increase production capacity and integrate cutting-edge technology and was completed in an unprecedented 48 days – setting a new global benchmark in the glass container industry.
The DF1 furnace rebuild encompassed a complete transformation of a 250 tonnes per day, 70-square metre container glass furnace. This ambitious project required meticulous planning, world-class execution, and flawless coordination to deliver within the exceptionally short time frame.
Key highlights of the project
- Refractories – Demolition and reinstallation of 2,000 MT of refractories, including hot sealing.
- Steel structures – Dismantling, modification, and reinstallation of approximately 90 tonnes of steel works.
- Furnace equipment – Installation of advanced exhaust draught systems, dampers, batch chargers, boosters, probes, cameras and cooling tower relocation.
- Working end & forehearths – Installation of gas reduction units, blowers, burners and state-of-the-art combustion and cooling skids.
- Utilities – Replacement of old water lines with stainless steel across 26 circuits and new air and gas pipelines.
- Combustion & cooling ducts – Fabrication and erection of new ducts, nozzles, skew ducts, blowers and fans for five forehearths.
- Electrical works – Installation of MCC panels, cabling, trays and instrumentation.
- Forming and inspection – Overhaul of three IS forming machines, two new forming machines and installation of an advanced cold end inspection system featuring AI and smart technology.
- Control system upgrade – New PLC, touchscreen HMI, temperature controllers and safety relays.
- Production flexibility – Integration of NNPB (narrow neck press and blow) and Blow & Blow technologies for lightweight food jars.
The DF1 Furnace Rebuild was led by Chief Operating Officer Jagdish Agarwal, whose leadership ensured flawless execution marked by zero accidents and robust risk management protocols. A special task force of 130 overseas contractors worked in coordinated 24-hour shifts, enabling rapid progress and precision.
The project also benefited from close collaboration with key global suppliers, including BDF Industries, Furnotherm, All Glass, Bottero and Tiama, whose expertise and support were instrumental in achieving this record-breaking milestone.