BDF Electric Forehearth: A New Era in Glass Conditioning -2025

BDF Industries has been a pioneer in glassmaking technology for about 120 years, continuously innovating to meet industry demands.

With a strong legacy in designing and manufacturing state-of-the-art melting, forming, and automation solutions, the company has introduced groundbreaking advancements in melting systems, thermal conditioning, and energy efficient solutions that enhance productivity and sustainability.

Some of BDF Melting’s most notable innovations include:

•  Advanced Combustion Systems: Enhancing efficiency in glassmelting and reducing NOx emissions also by means of technology like Natural Gas Continuous analyzer and servo actuated burner support.

•  Automation and Process Control Solutions: Integrating digitalization into glass production for increased precision like the BDF Forehearth Close Loop and the Panorama 4.0 suite.

• Hybrid and Electric Melting Technologies: Pioneering alternative solutions to traditional combustion-based glass melting. As well as the installation of an enthalpy recovering system like the ORC plant in container glass. The development of the All Electric Radiative Forehearth is another testament to BDF’s commitment to technological excellence and environmental responsibility.

Conventional forehearths rely on combustion, which introduces several challenges:

• Despite technological advance-ments (e.g., oxygen analyzers, combustion skids), controlling combustion variables remains difficult, leading to inconsistency in glass conditioning.

• Handling flammable gases, par-ticularly LPG, poses some safety risks.

•  Combustion generates CO2 emissions and other pollutants. For example, burning 1 kg of CH4 produces approximately 2.75 kg of CO2.

• The combustion process lacks heat recovery, leading to energy waste and increased operational costs.

Reducing CO2 emissions is a priority for the glass industry.

While the melter remains the primary source of carbon emissions, improving forehearth efficiency represents a significant step toward overall sustainability. Transitioning to an electric heating system offers a viable strategy to reduce the carbon footprint and support future decarbonization efforts.

Electric heating solutions are aligned with the EU’s Fit for 55 Package, which aims to reduce greenhouse gas emissions by 55 percent by 2030. As carbon pricing mechanisms become more stringent, glass manufacturers must adopt technologies that ensure compliance while maintaining cost-efficiency.

The BDF Electric Forehearth supports this transition by eliminating combustionrelated emissions and optimizing thermal control.

BDF’s innovative forehearth solution incorporates electrical heating element technology to transfer energy through radiation. Unlike traditional systems, it does not require electrodes in direct contact with the glass that may cause defects in the articles.

Key benefits include:

• Zero Exhaust Losses: Without combustion, there are no exhaust gases, eliminating heat loss and increasing efficiency.
• Superior Temperature Homogeneity: The BDF All Electric Radiative Forehearth ensures a high homogeneity index in the glass. Thanks to an advanced control system using SCR (Silicon Controlled Rectifiers), the system groups a limited number of radiant elements per zone, allowing for side-by-side heating control. This design provides finer and more precise temperature regulation compared to flamebased systems, minimizing thermal gradients and enhancing overall glass quality.
• Significant Energy Savings: A CFD simulation study conducted on a 70 tpd production line, starting at 1250°C and targeting 1120°C, and considering a thermal efficiency of 99 percent. Compared to traditional combustion-based forehearths, this results in an energy consumption reduction in kilowatts of more than 80 percent. The absence of exhaust gas losses and the precise electrical heat control contributes to unparalleled efficiency, leading to both economic and environmental benefits.
•  Improved Safety: By removing combustible gases from the process, operational risks are significantly reduced.
•  Greater Flexibility: Electric heating allows finer adjustments in temperature control, improving glass quality and process stability.

One of the most compelling aspects of the BDF Electric Forehearth is its dual advantage of economic and environmental sustainability. Traditional systems are subject to fluctuations in natural gas prices and carbon taxation, creating uncertainty in operational costs. By contrast, electric forehearths provide more predictable expenses since they rely on stable electricity pricing and are not subject to carbon penalties.

Moreover, energy efficiency improvements translate into lower energy consumption per ton of glass produced, reducing overall production costs while significantly cutting emissions. This contributes to a lower carbon footprint, supporting the industry’s transition to a more sustainable future.

In addition, manufacturers investing in electrification are eligible for green incentives, including funding for low-carbon industrial processes.

This further enhances the long-term economic viability of the BDF Electric Forehearth as a preferred solution for glassmakers seeking sustainability without compromising profitability.

BDF’s reputation for reliability and innovation is a key differentiator in the market. The All Electric Radiative Forehearth is designed with advanced monitoring systems that track power absorption in heating elements. This allows operators to anticipate aging and adjust parameters accordingly, ensuring optimal performance with minimal manual intervention.

Additionally, the control system design, robust and intelligent,

enhances operational stability, reduces downtime and maintenance cost, due to smooth interchangeability of the elements.

These factors make the

BDF Electric Forehearth a future-proof solution that aligns with the glass industry’s need for efficiency, safety and sustainability.

BDF also offers customized engineering solutions, allowing manufacturers to integrate electric forehearths into existing production lines with minimal disruption. This flexibility ensures a seamless transition to electric heating while maintaining high operational standards.

The BDF Electric Forehearth represents a significant advancement in glass conditioning, offering improved energy efficiency,enhanced safety and environmental benefits. By adopting this technology, glass manufacturers can achieve greater sustainability while reducing long-term operational costs. BDF Industries continues to lead the way in innovativeglassmaking solutions, reinforcing its legacy as a trusted partner in the industry’s transition toward a greener future.

As global policies drive industries toward decarbonization, solutions like the BDF Electric Forehearth are expected to be instrumental in ensuring that the glass sector remains competitive, sustainable and forwardlooking. With nearly 120 years of experience, the company reports

today that it remains committed to pioneering high-performance, ecofriendly innovations that can set new standards in the industry.