Clean, white glass cullet after processing.
DCS reverse jet filter units and cyclone.




Almost one million tonnes of glass bottles and jars are recycled annually in the UK. This figure represents around 40 per cent of all glass container waste and is set to increase to 60 per cent by 2008, if targets imposed by the EU Packaging Waste Directive are to be achieved.

At its Alloa - based plant, O-I (formerly United Glass), uses recycled glass in all its new bottles and jars. The Scotch Whisky industry is at the heart of the company’s spirits business, with the Alloa plant producing around half of all Scotch bottles.

The company operates its own Recycling Centre; with the capacity to process 100,000 tonnes a year of used glass collected from around Scotland.

Pre-sorted green, amber and white glass container-waste arrives at the recycling centre and is stored in separate bays prior to processing. A large loading shovel feeds the sorted glass waste into a hopper, from where the material is transported by conveyor through a series of screens and roll crushers that reduce the glass to the required cullet size for use in the glass furnaces.

Although bottle tops and other unwanted items are removed by a system of metal separation, laser beams and picking stations, the effective removal of dust and paper particles from bottle labels had proved a continuing problem.

Barry Chalmers, who is responsible for the operation of the treatment plant explains: ”It’s vitally important that we remove paper from the cullet because it turns into ash in the furnace and can create flaws in new bottles.The original dust extraction plant had struggled to cope in meeting the target flow of 25 tonnes per hour and the abrasive nature of glass dust had caused excessive wear throughout the system”.

It was decided to scrap the old system and install a new heavy-duty plant from dust extraction specialists, Dust Control Systems Ltd of Dewsbury, West Yorkshire.

Before presenting their proposals, Dust Control Systems carried out a thorough on-site survey to fully evaluate O-I’s requirement and to identify the shortcomings of the previous system.

The new filter plant consists of two large Reverse Jet Filter Units and a high efficiency Cyclone pre-separator designed to handle 28,000 m3/hr. To minimise the wearing effects of glass particles on the plant, removable wear-plates were incorporated throughout the system and special heavy gauge ductwork installed.

The plant was installed within a two week shut down period and is now efficiently removing paper, alloy cap rings and dust particles at levels that enable cullet throughput in excess of required targets. 


Dust Control Systems Ltd., Horace Waller VC Parade, Shawcross Business Park, Dewsbury, WF12 7RF
Telephone: +44 (0)1924 482500   E-mail:
Freephone: 0800 0407116

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