The information below highlights some of the recent projects GTS Environmental have taken part in recently further project reports can be found on the Consultancy Pages of this site.

The development of a manufacturing process to produce masonry units from recovered TV and computer screens. Currently, a start-up company is developing technology to bring the process to the commercial market. This will provide local employment and consume recovered glass that would otherwise go to landfill.

Project Summary

Staffordshire University has developed and patented a new technology (known as "Stoneglass") which can convert virtually any type of waste glass into commercial quality masonry units (bricks, pavers and cladding tiles). In particular, this process has the potential to rapidly expand a new end market opportunity for cathode ray tube (CRT) panel glass in line with the need for its more responsible recycling with the implementation of the Waste Electrical and Electronic Equipment (WEEE) Directive. Moreover, the new technology allows the use (and thereby expanded recycling opportunities) for other widely available waste glass streams that demand similar disposal attention such as automobile, fluorescent tube, plate and lamp glasses. It could also recycle considerable quantities of container glass (e.g. green and amber bottles). The Stoneglass technology allows the production of a wide range of masonry units whose features include:

• use of waste glass as its primary feedstock to give an end product with a glass content of ~97% by weight;
• a low processing energy requirement compared with traditional clay brick production due primarily to its significantly lower firing temperature;
• minimal emissions during manufacture; and
• versatility to replicate the functionality, appearance and properties of traditional clay, concrete and silica lime products.

Potential products include decorative cladding, block paving, paving slabs, cobbles, garden rocks, patio slabs, tiles and bricks. The light body colour of the waste glass feedstock means that an extensive range of through-body colours and surface patterning can be easily applied. This WRAP project was a collaboration involving Staffordshire University, a university spin-off company, a market research company and a specialist glass consultancy. Information and data for a commercial feasibility study were obtained from the production of bricks, pavers and cladding tiles using different mixes of CRT panel glass and container glass in a prototype pilot plant installed in the laboratory at Staffordshire University.

The project confirmed that the new process is ready for commercialisation and demonstrated the potential to reuse large tonnages of CRT panel glass and container glass which may otherwise go to landfill. The incorporation of Cathode Ray Tube Panel (CRTP) glass in combination with waste container glass in the Stoneglass masonry product range was shown to be non-harmful. The feasibility of mass production of the Stoneglass product range was confirmed by applying a costing model to the design of a turnkey brickworks and tile production plant. The high cost of third party supply of milled glass and concerns about security of feedstock supply prompted the drawing up of a detailed specification and costing of a ‘front end’ glass processing plant.

An extensive market survey embracing building product wholesalers/retailers, the construction industry, architects and designers, local authorities and the general public produced a favourable response from all sectors. The survey highlighted the potential application of the Stoneglass product as a cladding unit in prefabricated building products and other applications. Successful market penetration will depend on being able to demonstrate value added features. A good BREEAM ecopoints assessment would help to provide differentiation. Testing by an independent UKAS accredited laboratory confirmed that the bricks, pavers and cladding tiles produced using the Stoneglass technology met relevant BS: EN Standards for existing clayware products. Environmental exposure studies have been set up on the university campus and, in collaboration with Stoke-on-Trent City Council, test panels of the Stoneglass pavers have been laid in a pedestrian walkway area.

An environmental impact assessment demonstrated that the resource requirements and carbon dioxide emissions during production are significantly lower for the Stoneglass masonry products than for traditional clay brick products. There is no need for additional precautions over traditional clay products during the handling, installation and end-of-life disposal of the Stoneglass products. These masonry units also offer the advantages of an absence of crystalline silica (classed as carcinogenic if inhaled) and the potential for closed loop recycling.

Final report

Managing a WRAP project which is light weighting food and beverage containers, by designing out excessive packaging. This process involves managing the whole supply chain from food/drink producers, through to retail.

Beer, Cider and Spirits Project Summary

"Bottle Rightweighting - a process of packaging design and production to optimise packaging weight, whilst taking into account the requirements of all stakeholders in the supply chain, including manufacturers, brand owners, fillers, retailers, consumers and the environment".

Glassrite Beer Cider and Spirits, a WRAP funded project delivered by GTS Environmental, ran from January 2007 to March 2008. The project supported the supply chain for the beer, cider and spirits sectors in rightweighting the bottles they used. The project successfully met and surpassed its target to remove 20,000 tonnes per year from the UK waste stream, and supported the development of a culture in which rightweighting is a central consideration in bottle re-design.

The Drive for Packaging Reduction

There is considerable drive in the UK to reduce the amount of packaging consumed across all sectors. This is embodied in the EU Packaging Waste Directive, and at a more local level, the Government Waste Strategy, the activities of WRAP and its Courtauld Commitment, and Envirowise. Drivers include reduced raw material consumption, a reduction in waste to landfill and associated carbon emission savings.

However, beyond the environmental arguments, there is a strong business case for packaging reduction due to the cost savings, process efficiencies, and marketing possibilities it offers to the supply chain. This can be achieved either through engineering out unnecessary elements of packaging, or as is the case here, rightweighting one element of the total packaging solution.

Glassrite Beer, Cider and Spirits Activities

The project has worked extensively with stakeholders in the beer, cider and spirits sectors, and in particular brand owner-fillers and the UK glass manufacturers, to highlight the benefits of rightweighting, and identify rightweighting opportunities within brand portfolios.

The project has supported brand owners in the development of these opportunities and in addressing barriers which could slow or prevent initiatives reaching market. Key barriers addressed through the project have been bottle fitness for purpose during filling, transit and consumption, and also critically, marketing image and consumer perceptions of rightweighted bottles.

Through representation at seminars, conferences and stakeholder meetings, along with project newsletters and press releases, significant profile has been given to the rightweighting agenda, and some of the early achievements under the project. These activities have helped to raise awareness of these achievements and the benefits and possibilities of rightweighting.

Project Achievements

Through its activities, the project has identified and supported more than 15 rightweighting initiatives, delivering glass savings from the UK waste stream of ~32kt per annum, against the project target of 20kt. An associated carbon emissions saving of some 22,000 tonnes of CO2 has been achieved.

Participants have variously undertaken such initiatives in the name of reducing glass and PRN liability costs, improving process and line efficiencies, meeting retailer requirements for packaging reduction and shelf ready packaging, reducing their environmental impacts, and refreshing and enhancing marketing image. These initiatives demonstrate that significant rightweighting can either take place without noticeably changing bottle appearance or indeed, be used to enhancing a brand's marketing appeal.

The relatively low number of initiatives and tonnage achievement in the spirits sector is strongly associated with a high barrier to weight reduction which is closely linked to the premium brand image in this sector, perceived consumer expectations, and the needs of a largely export market. In addition, due to the low run numbers on many of the premium brands, residual mould costs for existing designs can represent a significant cost barrier. However, through project activities there is evidence of increasing sector interest in and debate around the issue of rightweighting, and previous work in the sector to lightweight highstreet name blended brands should not be overlooked.

Additional Research Undertaken

Beyond achievement of delivery of tonnage savings, the project has delivered a number of pieces of research including:

• The impact of rightweighting on the light protection offered by glass - showing that protection against lightstrike is not significantly compromised by rightweighting.
• The future of forming technology - this study has highlighted that technological possibilities exist for further lightweighting of containers, beyond current technologies, but suggests that the development and use of such technologies is strongly interlinked with societal demands, and the operational needs of the glass manufacturers; and
• A spirits brand consumer perception study - this work demonstrated that strong consumer appeal can be maintained in a rightweighted spirit bottle.

Recommendations

In order to maintain the momentum created during the project and encourage replication of its achievements, significant advocacy work should take place going forward. This could include further events, ongoing one-to- one contact with brand owners and retailers, and the development of case studies, and trade press articles highlighting the achievements under the project.

Recognising the particular spirits sector premium image / premiumisation issues identified through the project, it is recommended that an audit of spirits bottle weights be conducted to better understand where the opportunities lie in this sector, and critically, an extended spirits consumer perception study to advise the thinking of marketeers in the spirits sector.

Acknowledgements

The achievements of this project have relied heavily on the commitment, energy and enthusiasm of a wide network of participants. Particular thanks go to:

• The brand owners, for their commitment to the rightweighting ethos, and willingness to share their achievements with the wider sector;
• The UK glass manufacturers, who provided much of the technical "know how" and design capabilities underpinning the project;
• The Project Steering Group, for their enthusiasm and guidance in support of the project and its aims;
• The Proposal Approval Group, for their very considerable efforts in support of the project funding mechanism proposal, and the wider project support from the sector associations they represent; and
• WRAP, for their support and enthusiasm during the project, and for the funding which made this project possible.

Wine Project Summary

GlassRite Wine, a WRAP funded project delivered by British Glass, ran from July 2006 to March 2008. The project supported the supply chain for the wine industry in rightweighting the bottles they used and maximising the opportunity to bulk import wine and fill in the UK. The project successfully delivered new lightweight wine bottles into the UK and substantially increased bulk importation and UK filling. This reduced the amount of glass in the UK waste stream and increased the demand for recovered glass back into new wine bottles.

The project has contributed CO2 saving of over 28,300 tonnes/annum by increasing bulk importation of wine for UK filling by 79 million glass bottles which has in turn increased the use of UK recycled glass due to increased UK wine bottle manufacture by 23,930 tonnes/annum and reduced glass packaging for wine by 11,397 tonnes/annum due to lightweighting. The Drive for Packaging Reduction There is considerable drive in the UK to reduce the amount of packaging consumed across all sectors. This requirement is embodied in the EU Packaging Waste Directive, and at a more local level, the Government Waste Strategy, the activities of WRAP and its Courtauld Commitment. Drivers include reduced raw material consumption, effective use of recycled materials, a reduction in waste to landfill and associated carbon emission savings.

Beyond the environmental arguments, there is a strong business case for packaging reduction due to the supply chain in terms of cost savings, process efficiencies, and marketing possibilities it offers. This can be achieved either through engineering out unnecessary elements of packaging, or as is the case here, increasing bulk importation of wine for UK filling and using lightweight bottles.

GlassRite Lightweighting and Bulk Importation Activities

The project has worked extensively with stakeholders in the wine supply chain, and in particular retailers, brand owner, fillers and the UK glass manufacturers, to highlight the benefits of bulk importation of wine for UK filling and lightweighting. The project has supported retailers and brand owners in the development of these opportunities and in addressing barriers which could prevent initiatives reaching the market. Key barriers addressed through the project have been the effect of UV and bulk importation on wine quality, CO2 impact of wine transportation, lightweight bottle strength and consumer perceptions of lightweighted bottles.

Through representation at seminars, conferences and stakeholder meetings, along with project newsletters and press releases, significant profile has been given to bulk importation of wine for UK filling and the lightweighting agenda.

Project Achievements

The project has identified and supported more than 10 initiatives for bulk importation of wine for UK filling and lightweighting and these are summarised in this report. In addition, the project has gained commitment from many companies from the wine supply chain and has the momentum to engage further in bulk importation of wine for UK filling and lightweighting. The project has achieved glass savings from the UK waste stream of approximately 11,397 tonnes/annum and an associated carbon emissions saving of some 7,810 tonnes of CO2.

Bulk importation of wine for UK filling has increased by approximately 79 million 75cl bottles (from 120 million to 199 million 75cl bottles during the project period). This move has consumed an additional 23,930 tonnes/annum of recovered glass back into closed loop recycling i.e. using recycled glass to make new wine bottles in the UK.

The additional use of recycled glass will save approximately 7538 tonnes of CO2. In addition, from the Life Cycle Emissions study (section 5.4) it has been reported that when bulk importing and filling in the UK in a standard weight 75cl wine bottle from Australia (majority of wines filled in the UK are from southern hemisphere) there is 164g CO2 per 75cl wine bottle saving. Based on 79 million 75cl additional units per annum this would equate to approximately 12,950 tonnes of CO2. Therefore, bulk importation of wine for UK filling has saved in the order of 20,495 tonnes of CO2.

Additional Research Overview

Beyond achievement of delivery of tonnage savings, the project has delivered a number of pieces of research including:

• champagne and sparkling wine bottles - an assessment of the commercial and technical barriers to lightweighting Champagne, sparkling wine and semi sparkling wine bottles;
• consumer perceptions of lighter weighted wine bottles - an assessment of the correlation between the consumer’s perception of a wine’s value and the bottle design and weight;
• effect of ultraviolet light on wine quality - a desktop study reporting on the effect of UV on wine quality, the effect of reducing glass thickness due to lightweighting and how UV protection can be maintained;
• life cycle emissions of wine imported to the UK - a desktop study to investigate the CO2 impact of wine transportation, both bottled at source and bulk importation and then UK filled in lightweight bottles;
• lightweight glass containers - a study to investigate the strength of wine bottles and how lightweight bottles perform against standard weight bottles in term of strength and fitness for purpose; and
• shipping wine in bulk - a desktop study to investigate the effect on quality when shipping wine in bulk and logistical benefits.

Recommendations

This study has both raised awareness of the benefits of bulk importation and lightweighting and delivered significant savings. In order to maintain the momentum created during the project and encourage further uptake of its achievements, significant advocacy work should be continued. This could include further events, one-to-one contact with retailers, brand owners, fillers, international glass manufacturers, the development of case studies, and trade press articles highlighting the achievements under the project.

In addition the advocacy role would require working closely with groups and/or individuals that have been briefed on the project and were familiar with all the supporting research that has been undertaken. This would necessitate the advocates to undergo training and support by the project team. This process would need to be closely managed to ensure the correct message is being disseminated, and engagement in glass packaging reduction and bulk importation of wine for UK filling continues to grow. Also, there will be a requirement to continue the monitoring of the impact of the project.

Acknowledgements

British Glass would like to acknowledge the support of all elements of the supply chain without which this project would have not have been possible. The Project Steering Group and WRAP's Retail and Manufacturing teams deserve specific mention for their commitment and involvement in the project and contribution to its many successes. Special thanks are also extended to Oakdene Hollins for their contributions throughout and to theUniversity of Wales, Bangor, and the University of Sheffield, for their expertise in the specialist studies produced.

Project Website

Glass Market Development Assessments for the English Regions and the Devolved Administrations. This study gave an overview of the UK supply chain for recycled glass by looking at the estimated arisings of different glass types, current collections levels, and existing and potential markets in each region.

Project Summary

This study aims to give an overview of the UK supply chain for recycled glass by looking at the estimated arisings of different glass types, current collections levels, and existing and potential markets in each region. Part one of the report details the sources of data used and outlines potential markets and collection methodologies for recycled glass and an indication of the economics of these markets. Based on the data gathered part two attempts to identify plausible areas of further investigation or development in each region in order to promote the environmental and economic benefits of glass recycling on a regional basis.

The study utilises data from the DEFRA WasteDataFlow survey from October 2005 to September 2006 and is supplemented with information from British Glass and a survey on colour separation carried out for WRAP by Enviros. Additional information on current and prospective alternative markets has been gathered by literature and internet searches. This study does not consider wholesale changes to the way in which containers are used and recycled in the UK, or material substitution in container use.

Although the situation varies from region to region general conclusions that apply to the country as a whole are summarised below.

1. All regions have collection schemes in place for container glass using a combination of bring sites (bottle banks) and kerbside collections. No region has 100% of the population serviced by kerbside collections. In expanding kerbside collections consideration should be given to availability and quality requirements of end markets. Colour separated collections are preferential if glass is destined for closed loop applications such as container manufacture. Colour separated glass commands a higher price when sold on to reprocessors which will at least partially offset the additional collection cost. Glass collected as mixed colour is acceptable to glass processors who have sorting facilities providing the size fractions are large enough to be colour detected by the sorting equipment (approx 10 mm and above). Mixed glass is also suitable for alternative markets such as grinding and crushing for aggregates use etc.

2. There are few regions with schemes designed to collect window and other flat glass. If collected in an uncontaminated state this commands a high price. Collection schemes as part of a multi-material scheme with the aluminium and UPVC that make up double glazing units can increase profit levels.

3. Currently, and considering existing packaging requirements and UK supply chain, the most environmentally beneficial use for recycled glass is to return it to glass manufacturers for remelt into new glass products such as containers. This saves both energy and reduces the use of virgin raw materials, both of which lead to a reduction in carbon emissions.

4. Using glass cullet in the manufacture of fibre glass has similar benefits in terms of energy and raw material saving as remelting by the glass industry. At present the glass used to make fibre can only be recycled that once, rather than recycled infinitely such as glass containers after each use by the consumer. However, once installed fibre glass will have a long life expectancy (typically 20+ years) in comparison to glass packaging/containers whose life expectancy is likely to be nearer to 1 year.

5. There is more green glass collected than can be used by the UK container glass industry. Under current market conditions the most environmentally beneficial options for this surplus are to either export it to overseas container manufacturers, or to use it within the UK fibre glass manufacturing industry.

6. The use of recycled glass for aggregates is an established market in the UK, and although closed loop applications such as remelt offer better environmental benefits the aggregates route is an appropriate option for glass that does not meet the quality requirements for closed loop uses.

7. Trials and small scale commercial operations have proven the use of recycled glass in building products and as an active filtration media for water treatment. There is reluctance from customers to pay a higher price sometimes associated with glass based products compared with traditional materials. Increases in the landfill tax or increases in procurement decision making on an environmental basis could alter the economics and boost demand in these markets which could provide the impetus for regional production.

It is intended that regional partners use part two of this report to identify areas for further investigation. Part one and the bibliography provide background information to the options suggested. This study is intended as a starting point only and a more detailed feasibility study and economic model would be required before progressing the opportunities identified.

Final report

Creation of a Specification and Good practise Guide for the Supply of recycled materials to Flat Glass Manufacturers. This project included the development of a cullet specification and good practise guide for flat glass back into flat remelting.

Project Summary

The UK window (flat) glass industry currently recycles approximately 10% of the estimated 500,000 tonnes of such glass entering the waste stream each year. The industry has the capacity to recycle more recovered glass (cullet), but is prohibited by the availability of good quality uncontaminated supplies. Contamination is a critical issue for all glass manufacturers as trace levels are sufficient to cause glass defects. The flat glass sector has particularly high optical quality requirements and a small number of defects can result in large production losses which can negate any advantage of recycling.

Currently no public specification exists for flat glass cullet used in flat glass manufacture nor is guidance given on its collection. Such guidance has been produced for container glass and has proven to be a useful tool. The main aim of this project was to help increase the volume of good quality flat cullet, by producing the following guidance documents:

A specification for flat glass cullet used in flat glass manufacture. This specification is a guide to the cullet processor as to the quality of cullet which will be acceptable to the glass manufacturer, subject to local agreement between both parties.

A good practice guide (GPG) for collection of flat glass for use in flat glass manufacture. The GPG is aimed at the window manufacturers who produce waste glass in the form of manufacturing off-cuts and rejected sealed units and who may also collect post consumer flat glass. The purpose of the guide is to explain the contamination issues and give advice on which glass types are permitted within the clear and mixed cullet streams. The guide also sets out good practice for collection, storage and transportation of recovered flat glass.

Both documents were produced following consultation with the UK flat glass manufacturers and cullet processors who attended steering group meetings throughout the project. Each glass manufacture provided their cullet specification for review and visits were made to the processors and glass manufacturers to discuss current practice and issues.

Samples were collected at each site to assess the quality of cullet currently available, and to assess the practicality of regular sampling as a method to assure quality. The samples taken subjected to a range of testing including: moisture, organic content, particle size, tinted glass, contamination and chemical composition. The data from this exercise in conjunction with the manufacturers own specifications were then used to produce the guide cullet specification.

The guide recognises the inherent difficulties in obtaining a representative sample from unprocessed flat glass waste. It concludes that, due to the nature of the material and the physical difficulties and time involved, standard sampling methods do not offer a practical basis on which to operate a routine quality control regime

Acknowledgement

GTS would like to thank the organisations that assisted with the production of this report and associated documents.

CONGLASSCRETE I and II in conjunction with University of Sheffield, GTS investigated the use of waste glass in concrete products including finely ground waste glass as an additive material in cement manufacture.

Phase 1Summary

This project has conducted what is believed to be the widest-ever study of the performance of crushed and ground glass in real concrete products as a replacement for cement and/or aggregate. A total of 19 products, (98 mixes) were manufactured in precast concrete factories around the UK and tested for compliance with typetesting to British Standards, glass reactivity in alkali by the alkali-silica reaction (ASR) test and advanced chemical analysis including scanning electron microscopy by major concrete companies, Glass Technology Services and Sheffield University.

Full results are given within this report, but the major findings are that

i) all products made with glass as aggregate were found to have equivalent type-test results as products with no glass and

ii) after one year, dimensional tests indicate that detrimental reaction between the cement and glass only occurs when high-alkali Portland cement is used.

Whilst the findings above give considerable confidence to concrete producers, it is essential that the 98 product mixes, which remain in a conditioned environment at Sheffield, are tested for a longer period. Without this it is unlikely that glass aggregates could receive a 3rd-Party certification for use in concrete.

The project also conducted a very wide parametric laboratory study into the effects of glass aggregates in concrete. This study found that

i) glass can react in concrete and the reactivity increases with cement alkali content and particle size above 1mm, and

ii) that glass of particle size less than 1mm may reduce ASR effects.

Colour effects were unclear and it is felt that differences may be more related to crushing technique, which causes microcracks where ASR gel grows, than slight differences in glass chemistry. ASR suppressants were also investigated and this aspect of the project was extremely successful. Both dimensional measurements and scanning electron microscopy confirmed the following

i) the most important parameter affecting glass aggregate reactivity in concrete is cement alkali level,

ii) irrespective of glass type or particle size, the ASR reactivity can virtually be reduced to zero (at least in the short term) by using pulverisedfuelash (PFA), ground-granulated blast-furnace slag (GGBS) or metakaolin (MK) at normal replacement levels for Portland cement.

Specifications for glass as a pozzolan and an aggregate in concrete have been proposed. These are in a form that is similar to British Standards and could easily be adopted by industry. For glass aggregate, longer term testing of the Sheffield glass-in-concrete library is required to take this further than a tentative specification.

Phase 1 Final Report

Phase 2 Project Summary

This project has conducted widespread characterisation tests on the chemical properties of glass from the postconsumer, flat, lighting and fibres waste streams. Borosilicate and CRT waste glass are specifically excluded from this work. These results have shown that the chemistry of the glass in the waste streams tested had essentially similar major oxide contents. In addition it was found that the chemistry did not vary significantly between waste streams, nor between clean and contaminated sources of a single waste stream. The widest-ever study of pozzolanic reaction (which allows normally inert materials to contribute to concrete physical and chemical properties) between ground glass and cement was undertaken. 33 recovered glasses from various streams and sources were ground to a range of finesses, used to replace cement in mortar mixes and the fresh and hardened properties measured. The most important results from this work are

i) that glass reactivity in cementitious systems is more related to fineness than waste glass stream, source or degree of contamination and

ii) that glass ground to a fineness of >300m2/kg, irrespective of source, has a strength activity index equivalent to a conventional concrete pozzolan (fly ash to BS EN 450).

A specification for glass as pozzolan in concrete has also been proposed, based on the results obtained in this project and some 250 concrete mixes made and tested in the parallel ConGlassCrete 1 Project. BRE Certification have confirmed the work by overseeing duplicate testing at a UKAS-accredited laboratory and by publishing an independent Pre-Certification Report on glass pozzolanicity, developed from the work at Sheffield. These independent Reports are included in the Appendix D to this report. Three precast concrete products made with recovered glass as aggregate and/or pozzolan, selected from the 19 precast concrete products tested in the ConGlassCrete 1 Project, were subjected to independent 3rd-Party testing to assess their performance relative to control concrete made with no recovered glass and against the appropriate British Standards for the product type. In all cases, the products were compliant with British Standards and there was very little difference between the recovered glass samples and the control. Two independent Reports on these procedures, written by BRE and BRE Certification, are given in Appendix E to this report. Around 200 concrete mixes (100 made in factories as products and 100 made in the laboratory) are being kept incontrolled conditions at Sheffield for long-term testing. These are discussed in the body of this report and it is believed that these represent the single largest long-term study of glass in concrete in the world, with very high significance to the market. Currently, no funding is available to ensure that testing of these can be maintained.

Phase 2 Final Report

A market survey of applications and manufacturing processes of foam glass. BRE and GTS investigated the use of waste material to generate a building product or high value lightweight aggregate for insulation purposes.   

Project Summary

The aim of this project was to identify whether or not there are opportunities to either develop or transfer a foam glass production process into UK for manufacturing construction products. This information would then be used to advise the Waste and Resources Action Programme (WRAP) where best to invest i.e. transfer existing technology into UK, develop UK technology or not to invest in the foam glass process. This was achieved by completing four investigations by BRE and Glass Technology services. These include a market survey on the strength and changing nature of the UK construction industry, a literature survey of existing foam glass processes and products used in other countries, an investment appraisal (whole life costs) of the foam glass process using data from an operational plant and a large-scale pilot plant, an assessment of the best practicable environmental option (BPEO) for introducing the foam glass process into UK, and an assessment of using an alternative microwave energy system for the process.

The key findings of the survey include:

• WRAP should consider the transfer and optimisation of an existing foam glass technology from Europe for the manufacture of foam glass products in UK. Financial assistance will be required.
• The UK market for construction products has seen significant growth in the last decade and is expected to continue this trend with major capital investment in schools, health and housing. Foam glass is suitable for a number of construction products e.g. loose fill, insulation, blocks and slabs, and has characteristics of low flammability, thermal stability, high chemical durability and contains no fibrous material. There are well established markets that foam glass products should be able to penetrate by 1% to 5% without disruption to jobs and local economies.
• Both the investment appraisal and the Best Practicable Environmental Option assessment undertaken in this project have shown that the ideal size of a processing plant will produce 225,000/m3 of foam glass product requiring 50,000 tonnes of waste glass per annum. With this size of plant, the cost of foam glass products can be as low as £30/m3 and still provide a discounted payback period of about 4 years with an internal rate of return (IRR) of 30%. Foam glass products generally range from £30/m3 to £65/m3 for loose foam glass aggregate and up to £200/m3 for pre-shaped bricks, blocks, panels and insulation. The plant should be built within 100km of the main sources of glass waste which should be taken from the replacement window industry, end of life vehicles and cathode ray tubes. There is an economic benefit of using cullet from glass packaging waste, but this should only be used if it is heavily contaminated and not suitable for containers
• The use of continuous microwave radiation and exothermic reactions for heating the foam glass production process are currently not a viable option. Therefore the use of traditional forms of heating such as ovens should be used for the UK foam glass process.

Final Report