Repurposed and integrated colorant system enabling new green glass production with minimal capital cost
A leading glass manufacturer needed to add the capability to produce a new color of glass at its Colorado plant to support an upcoming product launch and time-bound production campaign. The facility was already producing flint (clear) and amber (brown) glass but lacked a system to premix and introduce green colorant into the batch process. Because of cross-contamination risks, the existing colorant system could not be reused. The client required a fast, cost-effective way to implement an entirely new colorant addition system on a six-month schedule and limited capital budget.
Re:Build Optimation performed a detailed assessment of an existing colorant premix system from a sister plant that had recently been decommissioned. Re:Build Optimation engineers, who had originally designed and installed that system fifteen years earlier, evaluated its condition, cataloged each component, and determined which elements could be refurbished and reused cost-effectively. The team then developed a plan to relocate, modify, and re-engineer the system to meet the plant’s specific footprint, process, and capacity requirements.
To minimize downtime and cost, Re:Build Optimation:
The relocated and upgraded system provided the plant with a dedicated green colorant premix and delivery system that operates independently from the existing amber and flint systems. By isolating each color stream, the plant eliminated cross-contamination risk and achieved precise, consistent dosing of colorant directly into the batching process. The new system delivers colorant as close to the furnace as possible to ensure optimal color consistency and quality.
Re:Build Optimation successfully relocated and modernized a complex process system from another state, delivering a fully functional, integrated colorant addition system within the $2.3 million budget and six-month timeline. The project enabled the client to launch a new production campaign for green glass, adding a major revenue stream without significant new capital investment or production disruption.
The system consists of:
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