Changing Patterns - Glass Sector Pilot Pioneering Sustainable Consumption and Production Chains

Project funded by British Glass Manufacturers’ Confederation and The Department of Trade and Industry March 2005 Peter Barden, Future Perfect Ltd

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Contents

Foreword iv

Acknowledgements vi

Executive Summary vii

1 Introduction 1 1.1 Background to the project 1

1.1.1 What is Sustainable Consumption and Production? 1 1.1.2 Collaborative projects 2

1.2 Glass sector pilot project 3 1.2.1 General approach 3 1.2.2 Workshop outcome 4 1.2.3 Project objectives and strategy 4

1.3 Methodology 6 1.3.1 Detailed methodology 6 1.3.2 Indicators 7

2 Overview of the UK Glass Industry and its Supply Chains 9 2.1 General overview of the sector 9 2.2 Container Glass Sector 11 2.3 Flat Glass Sector 11 2.4 Fibre Glass Sector 11 2.5 Special Glass Sector 12 2.6 Domestic Glass Sector 12 2.7 Industry Totals 12 2.8 Manufacturing inputs and outputs 12

3 Overview of the Glass Recycling Industry 16 3.1 Background 16 3.2 The Glass Recycling Industry 17 3.3 The Glass Reprocessors 18 3.4 The Bottlebank System 18 3.5 The Packaging Waste Regulations and Compliance Schemes 19 3.6 Local Authorities 20

4 Key Drivers and Forces for/against Change 22 4.1 Framework 22 4.2 Political 22

4.2.1 Legislative measures 22 4.2.2 Fiscal measures 22 4.2.3 Voluntary schemes 22

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4.3 Economic 23 4.3.1 Process costs 23 4.3.2 Process efficiency 23 4.3.3 Distribution/transport 23 4.3.4 Marketing issues 23 4.3.5 Brand image and value 24

4.4 Social 25 4.4.1 Demands/Inertia of Society 25 4.4.2 Resistance to change 25 4.4.3 Stakeholder perception 25 4.4.4 Investor demands 25

4.5 Technological 26 4.5.1 Process efficiencies 26 4.5.2 New processes 26 4.5.3 New products 26 4.5.4 Intellectual property 26

5 Benefits from the use of cullet 28 5.1 Reduction of materials to landfill 28 5.2 Avoidance of quarrying 28 5.3 Energy savings 28 5.4 Reduction of emissions 28 5.5 Increase of furnace life 28 5.6 Associated environmental costs 29

6 Findings 30 6.1 Structure of findings 30 6.2 Raw materials production & quarrying 31

6.2.1 Political 31 6.2.2 Economic 31 6.2.3 Social 32

6.3 Glass manufacture 33 6.3.1 Political 33 6.3.2 Economic 36 6.3.3 Social 39 6.3.4 Technological 41

6.4 Downstream customers 42 6.4.1 Political 42 6.4.2 Economic 44 6.4.3 Social 45 6.4.4 Technological 46

6.5 Waste stream and recycling 47 6.5.1 Political 47 6.5.2 Economic 49 6.5.3 Social 49 6.5.4 Technological 50

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7 Key issues 51 7.1 Political 52 7.2 Economic 55 7.3 Social 56 7.4 Technological 58

8 Project opportunities 60 8.1 Project opportunity 1 (Container Glass Sector) 60 8.2 Project opportunity 2 (Container Glass Sector) 60 8.3 Project opportunity 3 (Container Glass Sector) 61 8.4 Project opportunity 4 (Flat Glass Sector) 61 8.5 Project opportunity 5 (Flat Glass Sector) 61

9 Appendices 62 Appendix 1: Text of the initial “Letter of Request” sent to stakeholders 63

Changing Patterns 63 Appendix 2: List of stakeholders to whom the “Letter of Request” was sent 64 Appendix 3: List of organisations that were interviewed or visited 66 Appendix 4: Details of significant reports reviewed 69

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Foreword

Glass has played an important part in the development of civilization; providing the means to light, insulation, medicine and scientific research, safe food storage and now energy producing and saving products. It retains a vital role in the modern world, being an essential component to a wide variety of other industrial sectors. It is important that it is produced and consumed in a way which is environmentally sound, socially responsible and economically viable so as to allow future investment and so retain glass production and employment in the UK. This is all part of stimulating innovation in its broadest sense, social, institutional and technological, so as to achieve smarter and more resource efficient forms of production and consumption. Glass manufacturers have made significant progress in recent years in reducing their environmental impact particularly with regard to energy and CO2 through improved melting technology, pack rate and recycling. This has resulted in benefits in all key areas; environmental, social and economic. Through innovative research and development world class products exist which are in themselves capable of reducing adverse impacts elsewhere within the economy; such as in health, transport and Climate Change. Through extensive investment in capital and equipment over many years the industry has also become highly efficient and the UK manufacturers’ performance stands favourable comparison with any in the world. DTI and DEFRA jointly published in September 2003 Changing Patterns - UK Government Framework for Sustainable Consumption and Production which includes amongst key proposals decoupling economic growth and environmental degradation, improving resource efficiency and taking a whole life-cycle of a product, through design, production, use and disposal, to help reduce its effect on the environment. This Framework committed DTI and DEFRA to set up collaborative projects involving particular sectors or product chains as pilots to explore practical application of the SCP approach. British Glass and the Department of Trade and Industry jointly funded Future Perfect consultants to explore the practical application of the Sustainable Consumption and Production (SCP) approach within the glass sector and with a view to presenting it to the larger industry sector. This report was compiled by a consultant to British Glass, who conducted a series of interviews with relevant stakeholders in the glass industry and supply chain. Their views have been incorporated in the report but they neither necessarily reflect the Government or British Glass position nor are endorsed by the DTI or other Government departments. This pilot concentrated on two main areas: container manufacture and consumption, and particularly recycling; and the thermal glazing supply chain. The consultant was commissioned to follow up previous research undertaken in this area and to work with glass business sectors to identify the key actors, barriers and enablers to sustainable consumption and production in a product chain - and the specific points in the product’s life-cycle where taking action will most make a difference in improving environmental and social impacts.

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The desired outcome of this initiative was to improve the way products and services are designed, made, delivered, used and disposed of so as to provide greater value, performance and choice for the consumer, as well as improving environmental and social impacts. We hope that future collaborative projects between different stakeholders will help move a step further in this direction.

David Workman Director General, British Glass

Jonathan Startup

Director, Sustainable Development, DTI

February 2005

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Acknowledgements

This project report could not have been produced without the significant input and help of a large number of organisations and individuals who gave their time and shared their knowledge and experience so as to enable the information to be collated. I would like to thank all those who have assisted in the research of this pilot; many are named later in the report and I apologise if I have inadvertently omitted your name. The work was jointly funded by British Glass and the Department of Trade and Industry (DTI). Acknowledgement goes to the following for their assistance and advice:

♦ Andrew Hartley, British Glass

♦ Andy Hartley, British Glass

♦ David Workman, British Glass

♦ John Stockdale, British Glass

♦ Michael Massey, DTI

♦ Aphrodite Korou, DTI

Peter Barden

Director, Future Perfect Ltd.

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Executive Summary

Increasingly both Governments and Society at large are becoming conscious that Society’s profligate use of energy and natural resources, particularly in developed countries is unsustainable, and that something has to be done.

At the World Summit on Sustainable Development (WSSD) in Johannesburg in 2002 the UK Prime Minister and other world leaders committed themselves to “encourage and promote the development of a ten year framework of programmes ...to accelerate the shift towards sustainable consumption and production”.. . As part of this process the UK Government published in September of 2003 “Changing Patterns – UK Government Framework for Sustainable Consumption and Production”, which sets out how the UK Government intends to translate these commitments into practical action.

As one of the first steps to delivering Sustainable Consumption and Production (SCP), the Department for Environment, Food and Rural Affairs (DEFRA) and the Department of Trade and Industry (DTI) made a commitment to establish a number of collaborative projects involving particular industry sectors or product supply chains as pilots to explore the practical application of the SCP approach. The glass sector was chosen as one of these pilots.

DTI set up an initial SCP workshop which gave the opportunity to a wide range of stakeholders to jointly explore barriers, enablers, opportunities and priorities for action in the glass supply chain. The workshop also provided the basis and a framework for this pilot and subsequently a methodology was developed concentrating upon the canvassing of stakeholder opinion and the soliciting of their formal input to the project. This process followed the basic steps outlined:-

1. Supply chain mapping

2. Stakeholder mapping

3. Contacting stakeholders by letter

4. Telephone contact with key stakeholders

5. Key stakeholder interviews and site visits

6. Literature review

7. Report drafting

8. Presentation of preliminary findings at a workshop at the Environment Agency Conference (October 2004).

The project explored the structure of the glass supply chain from the point of production of the raw materials to the final disposal of the finished product at the end of its useful life. It intended to identify at each point in that supply chain the key barriers to, and enablers of, the principles of SCP, and to analyse them in terms of their political, social, economic or technological impacts. The project concentrated on two specific areas, namely the glass container sector and the utilization of thermally efficient glazing.

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The generic findings resulting from this research have then been incorporated in the report as a set of Key Issues, identifying areas where specific action could offer opportunities for the better implementation of the principles of sustainable consumption and production, reflecting relevant stakeholders’ views, other than Government. General principles have then been further refined into an initial, but non exclusive, set of five project opportunities whose aim would be to explore and encourage further collaborative action and take up so as to take forward the practical implementation of a number of the Key Issues :-

Project Opportunity 001: Glass Container Specification – Supermarket Own Label Brand

Project Opportunity 002: Glass Container Specification – Wine Bottle Specification

Project Opportunity 003: Glass Container Recycling – Increased recovery of container glass from licensed premises

Project Opportunity 004: Flat Glass Recycling – Development of a Good Practice Case Study

Project Opportunity 005: Flat Glass Recycling – Opportunities for the end of life recovery of components from the Replacement Glazing Sector

It should be noted that these five project opportunities reflected what was considered practicable, politically and economically, given the existing legislative and market environment. They did not necessarily reflect those priority areas of concern of individual stakeholders.

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1 Introduction

1.1 Background to the project

At the World Summit on Sustainable Development (WSSD) in Johannesburg in 2002 the UK Prime Minister and other world leaders committed themselves to:

“Encourage and promote the development of a 10-year framework of programmes in support of regional and national initiatives to accelerate the shift towards sustainable consumption and production, to promote social and economic developments within the carrying capacity of ecosystems by addressing and, where appropriate delinking economic growth and environmental degradation through improving efficiency and sustainability in the use of resources and production processes, and reduce resource degradation, pollution and waste…with developed countries taking the lead.”

As part of the UK Government commitments under this process it published in September of 2003 “Changing Patterns – UK Government Framework for Sustainable Consumption and Production”, which sets out how the Government intends to translate these commitments into practical action.

1.1.1 What is Sustainable Consumption and Production?

Building on the WSSD definition, the Government defines the core of Sustainable Consumption and Production (SCP) as:-

“Continuous economic and social progress that respects the limits of the Earth’s ecosystems, and meets the needs and aspirations of everyone for a better quality of life, now and for future generations to come.”

It continues to state that:-

“Given that there are limits to the capacity of the Earth’s ecosystems to absorb pollution and provide natural resources, the only way to maintain economic progress in the long term without approaching these limits is to decouple economic growth from environmental degradation:

• by ‘decoupling’ we mean ensuring environmental degradation does not automatically grow with the economy to the extent that environmental limits could be threatened in the medium term.

• by ‘environmental degradation’ we mean unsustainable use of natural resources – which embraces situations where we exceed the carrying capacity of the environment to absorb pollution.

In practical terms this means getting more for less:

• more efficient and profitable production, using less raw material.

• more value added to a product, with less pollution and waste in the process.

• more consumer needs fulfilled with less energy, water and waste.”

Attempts have been made to determine the scale of improvement in resource efficiency needed to achieve sustainable development, including the notion of halving inputs whilst doubling outputs (“factor four”) and possibly more in future decades. Others have

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argued that we need three planets’ worth of resources to sustain our current level of consumption across the globe. Whilst the estimates vary substantially, it is nevertheless clear that significant improvements are required to ensure sustainability into the future.

The UK Government states that this vision of SCP will be accomplished through:

1. ‘Decoupling’ economic growth and environmental degradation.

2. Focusing policy on the most important environmental impacts associated with the use of particular resources, rather than on the total level of all resource use.

3. Increasing the productivity of material and energy use, as part of the broader Government commitment to increase the productivity of the nation.

4. Encouraging, and enabling active and informed individual and corporate consumers who practice more sustainable consumption.

1.1.2 Collaborative projects

As one of the first steps to delivering SCP, the Department for Environment, Food and Rural Affairs (DEFRA) and the Department of Trade and Industry (DTI) committed themselves to establish a number of collaborative projects involving particular sectors or product supply chains as pilots to explore the practical application of the SCP approach. This approach would build on work the two Departments had undertaken on ‘sector sustainability strategies’ with industry partners in some sectors, but carry it through into some specific areas of consumption and production. In addition, this would be consistent with, and contribute to, the approach proposed in the European Commissions Integrated Product Policy (IPP) in some selected areas.

Initial ideas for work intended to include food and drink, construction and glass. This project forms the latter and has been commissioned by the British Glass Manufacturers’ Confederation (British Glass) and the DTI.

The aim of these projects is to work with business sectors to identify:

1. The key actors, barriers and enablers to sustainable consumption and production in a product chain.

2. The specific points in the product’s life-cycle where taking action will most make a difference in improving environmental and social impacts.

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1.2 Glass sector pilot project

The background and rationale for this glass sector pilot were developed in October 2003 at a scoping SCP workshop, set up by the DTI, in the aftermath of the Pioneers Group conference. British Glass and a wide range of stakeholders contributed to this workshop, with the aim of developing the scope and terms of reference of the project. The objectives of this meeting were to:

1. Identify key actors.

2. Identify barriers and enablers.

3. Identify specific points in the life cycle where taking action would make the most difference.

4. Map out main sustainability issues facing the glass sector.

5. Prioritise main barriers.

1.2.1 General approach

The meeting took the following general approach: The starting point would be the identification of the most significant environmental and social impacts of the product “from cradle to grave”. It was felt that in some instances this might involve a formal life cycle assessment.

1. Consideration would be given to the whole of production and consumption in order to identify the roles, interests and motivations of different actors at those specific points in the product’s life cycle where taking action might potentially make most of a difference in reducing environmental impacts.

2. Key barriers and enablers to reducing these impacts would then be identified, and these were felt to most likely fall within the following areas:

• Political

• Economic

• Social

• Technological

3. The development of specific proposals for business, government and other stakeholders.

4. It was felt to be of great importance that key issues raised, any recommendations made, or any actions taken, should not simply displace the problem from one part of product/consumption chain to another. The associated economic or social impacts, both positive and negative, should also be taken into account.

5. The project would encompass the use of glass throughout the economy from construction to food and beverage containers.

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1.2.2 Workshop outcome

The workshop identified two primary, but not exclusive, areas for initial study, namely:-

1. The manufacture and consumption of container glass, with particular reference to recycling.

2. Methods for encouraging the uptake of thermal glazing in both domestic and commercial buildings.

These were further explored to give the following project objectives.

1.2.3 Project objectives and strategy

1 - The manufacture and consumption of container glass

• Objectives

1. The identification of the major environmental impacts of the container manufacture and supply chain:-

o Raw materials input.

o Manufacture.

o Transport.

o Filling and packaging.

o Brand imaging with respect to environmental impacts.

o Product purchase, utilization and consumption.

o Reuse, recycling and disposal.

2. The identification of the different barriers to improved sustainability in the chain and the key stakeholders involved.

• Strategy

1. A review of existing publications and information.

2. The identification of the key elements of strategy (Government-led, industry-led and consumer chain-led) that impacts upon the glass supply chain.

3. The identification and approaching of key stakeholder groups.

4. The development of key indicators.

5. The quantification of the impacts.

6. The identification of barriers to, and enablers of, improved sustainability.

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2 – Encouraging the uptake of thermal glazing

• Objectives

1. The identification of the key elements of strategy (Government-led, industry-led and consumer chain-led) that impacts upon the thermal glazing supply chain, including:-

o Integration of UK climate change policies and other legislation.

o Consumer awareness.

o Government incentivisation.

o Environmental benefits.

2. The encouragement of the take-up of thermal glazing in existing domestic and commercial properties.

3. The identification of the various obstructions to this uptake and the key stakeholders involved.

• Strategy

1. The identification of potential UK energy savings to be made by the increased uptake of thermal glazing.

2. The identification of the various obstructions to this uptake and the key stakeholders involved.

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1.3 Methodology

1.3.1 Detailed methodology

The project methodology originally adopted for the Glass Sector Pilot is detailed in the table below.

Step Project Action Details

1 Supply chain mapping The detailed mapping of the glass supply chain in order to understand its structures, raw material sources, markets and disposal channels.

2 Stakeholder mapping The development of a stakeholder map in order to identify those stakeholders with either a direct, or indirect, interest in the glass industry and its supply chain, who might have a view or impact upon relevant SCP issues.

3 Stakeholder letter The drafting of a circular letter, addressed to all of the stakeholders identified in Step 2, with a view to inviting input, suggestions and comments on the project. A dedicated e-mail address was also set up. A copy of the letter sent, together with the list of organisations to which it was addressed, are given in Appendices 1 and 2.

4 Telephone contact with key stakeholders

A detailed review of the stakeholder list to identify key stakeholders for subsequent direct contact by telephone, either with a view to inviting comments over the telephone, or to arranging a formal interview or site visit.

5 Key stakeholder interviews and site visits

The completion of both telephone interviews and site visits to provide more detailed input into the project. Details of organisations visited or interviewed are given in Appendix 3.

6 Literature review The review of existing reports and literature concerning issues applicable to the project. Details of the more significant documents reviewed are given in Appendix 4.

7 Regular project reviews The conducting of project review meetings, with both British Glass and the DTI, in order to ensure that appropriate progress was being made with the project.

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Step Project Action Details

8 Preparation of written report (public draft)

The preparation of a formal draft report to be submitted for public consultation at a workshop hosted by British Glass (Step 9).

9 Workshop

(Step subsequently removed)

Key stakeholders would be invited to a formal workshop to consider the draft project findings and encourage further input to the consultation, to refine the project conclusions, and to identify the optimum way or ways forward.

10 Finalisation of report Completion of the written report to include feedback taken from the workshop given at Step 9.

This methodology was developed in collaboration between British Glass and the DTI in December 2003. Subsequently, the two parties agreed that Step 9 (Workshop) would not add additional depth to the findings of the project and was provisionally removed from the project programme.

1.3.2 Indicators

The Changing Patterns Framework Document identifies a “basket of indicators” for use with SCP which is given in the table below:

The Framework Document details a series of decoupling indicators, where environmental impacts are directly compared with either GDP and/or household consumption.

Economy-wide decoupling indicators 1. Greenhouse gas emissions 2. Air pollution 3. Water pollution (river water quality) 4. Commercial and industrial waste arisings and household waste not recycled.

Resource use indicators 5. Material use 6. Water abstraction 7. Homes built on land not previously developed, and number of households

Decoupling indicators for specific sectors 8. Emissions from electricity generation 9. Motor vehicle kilometres and related emissions 10. Agricultural output, fertiliser use, methane emissions and farmland bird

populations 11. Manufacturing output, energy consumption and related emissions 12. Household consumption, expenditure of energy, water consumption and waste

generated.

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For the purposes of the Glass Sector Pilot Project, these indicators were reviewed and further developed through literature review and stakeholder consultation to make them directly relevant and applicable to the glass sector supply chain. Key issues addressed during this phase of the project were:-

1. Relative magnitude of the environmental impact of the indicator

2. Relative impact in socio-economic terms of the indicator

3. Potential cost benefits associated with the indicator

4. Ease of access to the data

The base indicators used during the course of the Pilot Project are listed below:-

Headline SCP indicators defined and utilised during the Glass Sector Pilot Project:

1. Raw material usage.

2. Energy efficiencies (see chart 1 below).

3. Carbon emissions [both direct and indirect] (see section 2.8).

4. Air pollution.

5. Water pollution.

6. Waste production.

7. Recycling rates.

8. Motor vehicle kilometres and related emissions.

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2 Overview of the UK Glass Industry and its Supply Chains

2.1 General overview of the sector

The UK glass industry currently produces an estimated 2.8 million tonnes of glass per annum from all sectors, with a total saleable value of approximately £1.5 billion1.

The industry can conveniently be divided into five sub sectors as follows (available data relates to the situation in 2002):-

Sub-sector Annual Production (tonnes)

Percentage of total (approx)

1 – Container 1.70 million tonnes 61%

2 – Flat Glass 0.76 million tonnes 27%

3 – Fibre 0.15 million tonnes 6%

4 – Special 0.12 million tonnes 5%

5 – Domestic 0.01 million tonnes 1%

TOTAL 2.74 million tonnes 100%

1 Source of data in this chapter is “UK Glass Manufacture – A Mass Balance Study” published by British Glass under the Biffaward Scheme, 2003.

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The map below indicates the location of the major glass manufacturers in the UK

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2.2 Container Glass Sector

Container glass, mainly in the form of bottles and jars, accounts for over half of all glass production in the UK. In 2002, the UK container industry comprised seven manufacturers, operating 30 furnaces on 14 sites around the UK. Individual furnace capacities range from under 100 tonnes per day to those with a capacity of over 650 tonnes per day. The total (melting) capacity of this sector of the glass industry in 2002 was 7,000 tonnes per day (which is equivalent to approximately 2.5 million tonnes per annum).

The UK is, however, a net importer of container glass, with the majority of these imports being in the form of filled products, such as bottled wines and beers. This element includes a large, but unknown, quantity of product imported by the public via “duty free” and cross channel shipping. No formal system exists for the collection of statistics from filled products, but work carried out during the compilation of a recent report by British Glass suggested that the net import of container glass was in the region of 629,000 tonnes in 2002 (i.e. total imports less exports of filled containers). Thus the total container glass flow into the UK was estimated at 2.33 million tonnes in 2002.

2.3 Flat Glass Sector

Globally the demand for flat glass has been buoyant, fuelled by the demand for both building (i.e. glazing and architectural applications) and automotive glass. Over the last 20 years this sector has seen an annual increase of demand of approximately 5% year on year.

The UK currently has three manufacturers producing flat glass with the most recent addition coming on stream in December 2003. The estimated total capacity of the three manufactures is in the region of 1.0 million tonnes per annum, and total domestic production in 2002 was in the region of 760,000 tonnes.

As with the situation for container glass, the UK is a net importer of flat glass, and it was recently estimated by British Glass that the net inflow of flat glass into the UK was approximately 150,000 tonnes in 2002. However since that date a new float line has been added to the UK capacity and it is as yet unclear what effect this will have on the mass balance flow of UK flat glass manufacture.

The trade in motor vehicles is also responsible for a net in-flow of flat glass into the UK. Data from the DTI (2001) recorded UK Car production at 1.63 million units compared with new registrations of 2.22 million units which suggests a net import figure of 0.59 million units. Using a typical value of 33 kg of glass per vehicle a net import of approximately 20,000 tonnes of glass is derived.

2.4 Fibre Glass Sector

Production from this sector is estimated at 150,000 tonnes per annum. Continuous glass fibre has over 40,000 different applications including reinforcement of plastics and rubber, electronic blinds and wall coverings. It is a component in the manufacture of wind turbines for example.

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2.5 Special Glass Sector

The special glass group is the most diverse in terms of production processes and capacities. This sector encompasses products such as lighting, television tubes, oven hobs and specialist optical, medical and scientific products. Production capacities range from large 200 tonnes per day furnaces to specialist melters producing only a few kilograms per week.

In 2002, this sector comprised 13 operators with a combined output of around 120,000 tonnes per year, and a sales value of approximately £200 million.

2.6 Domestic Glass Sector

Domestic glass production covers products such as ovenware, drinking glasses and giftware. Due to aggressive overseas competition the UK currently has no volume producer of domestic glass ware.

The giftware sub-sector, which includes lead crystal melters, comprises around 20 manufacturers who typically operate small pot furnaces melting a few tonnes per week. The operations are relatively labour intensive and produce high value ware. Production from this sector is estimated at 6,000 tonnes per annum.

2.7 Industry Totals

An analysis of the total mass flows through the UK glass industry (in 2002) revealed a net flow of 3.6 million tonnes of glass within the UK economy. Some 2.8 million tonne is domestically produced with a net import contributing to a further 800,000 tonnes. Approximately 1.1 million or 30% if this glass is currently being recycled either within the industry or increasingly finding alternative uses such as aggregates or in some cases more exotic and value added products e.g. advanced filtration medium.

2.8 Manufacturing inputs and outputs

The information detailed in this section is taken from “UK Glass Manufacture – A Mass Balance Study” published in 2003 by British Glass as part of the Biffaward Scheme.

Sand (SiO2), limestone/dolomite (CaCO3 and MgCO3) and, soda ash (Na2O) are the principle virgin raw materials used by the glass industry, and approximately 2.5 million tonnes of these materials were used by the industry in 2002. In addition to this, a further 850,000 tonnes of recycled glass cullet was actually re-melted and reused within the manufacturing process.

The industry is not a large user of water, with average consumption being slightly in excess of 1m3 for each tonne of glass produced.

Glass manufacture is an energy intensive process, however, and the UK glass industry consumes approximately 8.6 giga-watt hours (GWh) of power per annum. Approximately, 80% of the fuel utilised is in the form of natural gas, the majority of which is used to fire the high temperature furnaces.

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Fuel Type Fuel mix (delivered basis)

Natural Gas 80%

Electricity 14%

Gas Oil 4%

Heavy Fuel Oil 2%

By virtue of the industry’s ability to recycle almost all of its own rejected ware, very little solid waste is produced. However, furnace rebuilds do produce a large amount of waste, but with a typical furnace life of between 12 to 15 years the net contribution to the waste stream from these events is relatively insignificant.

Air borne emissions constitute the single largest pollutant output from the industry. The combustion process converts fuel into carbon dioxide (CO2) and water vapour (combustion emissions), with some of the raw materials used containing carbon which is also liberated as carbon dioxide during the glass making process (i.e. process emissions). In total, approximately 1.6 million tonnes of carbon dioxide is produced directly by the glass industry (direct and process emissions), and a further 350,000 tonnes is produced by proxy at the power stations as a result of the electricity consumption of the industry (indirect emissions) every year.

The charts below show the percent reduction in direct CO2 emission since 1990 and this is compared to the amount of the carbon dioxide allowance available to the industry under the provisional National Allocation Plan (NAP) figures available at the end of 2004. The second chart shows how the industry is decoupling carbon dioxide emission from production and also gives projected production figures and emissions into Phase 1 of the EU Emissions Trading Scheme (EUETS).

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0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

1999 2000 2001 2002 2003 2004 2005 2006 2007

Millions of tonnes

Production CO 2 Emissions Production CO 2 Emissions

Glass Sector

PRODUCTION and Direct CO2 EMISSIONS (Fossil fuel and carbonates: decoupling)

100

77 65

54

NAP ?

0

20

40

60

80

100

1979 1991 1996 2003 2007

2

Direct CO2 Emissions, reduction on 1970 (Emissions of CO2 based on 1979 = 100)

NAP = National Allocation Plan

Glass Sector

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The glass making process also produces other airborne emissions, including:

• Sulphur dioxide (SOx) – 4,600 tonnes

• Nitrogen dioxide (NOx) – 10,600 tonnes

• Particulates – 1,500 tonnes

• Acid gases (HCl & HF) – small quantities.

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3 Overview of the Glass Recycling Industry

3.1 Background

Glass has always been a material that has been reused and/or recycled in the sense that bottles have been refilled and reused for generations.

Formal industrial reuse and recycling is also not a new concept in the UK, our system for home delivery of milk is often cited as being one of the best ever operated. A deposit system for beers and soft drinks was in widespread use until the 1970’s, and it was capable of delivering good rates of returns to locally based fillers. The first UK bottle bank, for recycling as opposed to reuse, was established in Barnsley in 1977.

That said, the current rate of recycling of container glass achieved in the UK compares very unfavourably with our European neighbours:-

Country Recycling Rate % (Container Glass)

Switzerland 92

Finland 91

Norway 88

Belgium 88

Germany 87

Sweden 84

Austria 83

Netherlands 78

Denmark 65

France 55

Italy 55

Ireland 40

UK 34

Portugal 34

Spain 33

Greece 27

Turkey 24

Source: “UK Glass Manufacture – A Mass Balance Study”, British Glass, 2003

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Several arguments have been and are advanced to explain the circumstances which cause the UK’s current under performance and these include:-

• The demise of the returnable container, as a result of more centralised beverage filling and distribution chains;

• The low density of bottle banks and other recycling facilities;

• The reluctance of local authorities to include glass in their kerbside collection schemes;

• The absence of statutory targets for waste collection authorities

• The absence of compulsory deposit scheme on beverage containers;

• Lack of education and awareness.

Several, mainly Government, initiatives in response to EU directives which are now in place should result in a large increase in the volume of glass collected and recycled or reused.

3.2 The Glass Recycling Industry

The glass recycling industry comprises the collecting organisations (who provide the glass for reprocessing (cullet)), the cullet processors (who process the recovered glass into a useable form) and the manufacturers who reprocess the materials into new product. Typically, the processors sort and wash the glass to remove unwanted materials such as metals, paper, plastics and various stones and other ceramic materials. In addition, cullet may well undergo some form of colour separation, before finally being crushed into the desired size.

Glass collection is primarily confined to arrangements between the reprocessors and the local authority through either, the bottle bank system, or through their waste disposal service kerbside collection schemes. At present, there is no systematic national recovery of container glass from licensed premises such as pubs and clubs, although some collection is carried out; nor is there an equivalent infrastructure for the collection of recyclable flat glass.

Historically the glass container manufacturing plants, and to a lesser extent the glass-fibre plants, were the sole reprocessors of post-consumer glass. Although some pre-consumer flat glass cullet is recycled, primarily through the flat glass manufacturer, some does reach the container industry. One flat glass manufacturer states that they are utilising 100% of pre-consumer recycled glass and off-cuts.

The great majority of glass currently available for recycling arises from either local authority initiatives (bottle banks, kerbside collections) or the glass collected via the drinks trade from pubs and clubs. In either case, the glass is effectively evenly spread across the country whilst the manufacturing plants tend to be concentrated in the north of the country which has a significant impact upon the economics of collecting in the southern half of the country.

The arrival of the Packaging Waste Regulations in 1997, with the attendant obligations to achieve target rates of recycling, has had a significant effect upon the established industry. The use of mix-coloured glass for aggregates has been one of the largest

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impacts of the regulations. It is estimated that approximately 100,000 tonnes per year of glass is currently being used as a road making aggregate substitute.

The “Waste and Resources Action Programme (WRAP)”, funded through DEFRA, the DTI, and the devolved administrations of Wales, Scotland and Northern Ireland has a number of projects looking at new and innovative uses for glass.

3.3 The Glass Reprocessors

Approximately 20 companies were registered by the Environment Agency as accredited glass reprocessors in 2002, this number rising to 37 in 2003 and 43 by 2004. Such organisations carry out the recycling and convert glass into new products. Only accredited reprocessors can issue Packaging Waste Recovery Notes (PRN). It must be stressed that these notes are only associated with glass used for packaging (i.e. container glass) and not other forms of glass waste, which of itself has influenced the efficiency of glass recycling generally (i.e. discriminating against other types).

3.4 The Bottlebank System

The first commercial bottle banks were introduced in Barnsley in 1977. Since then the system has expanded to cover most of the UK – see chart below. The 1000th bottle bank was commissioned in 1982. The scheme further expanded to the point in 1997 that there were a total of 22,074 such sites in operation. Since then the rate of expansion has slowed and the latest returns suggest a slight decline in their total number.

In 2002, some 20,796 bottle bank sites were established throughout England, Scotland and Wales. From these banks a total of 736,000 tonnes of waste glass was collected, which is equivalent to 34% of the volume of container manufacture.

In terms of bottle banks, the UK is a poor performer when compared to our European neighbours. The figure of 20,796 sites equates to a density of around 1 bank per 2,860 head of population, and values of 1 per 1000 are not uncommon on mainland Europe. A study carried out by the Dutch organisation, “Stichting Promotie Glasbak”, concluded that a ratio of 1:650 constituted the optimum collection efficiency.

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Commercial organisations, such as pubs and clubs, produce approximately 25% of the UK’s waste glass. The full potential for recovery from this source is demonstrated by the Brewers and Licensed Retailers Association Report which estimates that some 350,000 tonnes of glass could be recovered from their members premises alone.

There is a large disparity between the colour of glass that the UK container industry manufactures, and the colour of glass that is recovered through the bottlebank system. The primary reason for this mismatch is mainly due to the fact that the UK’s beverage exports tend to be in the form of clear bottles from the spirits trade, whilst imports consist largely of wines and beers in coloured bottles.

UK Container Market Manufacture (%) Recycled (%)

Clear 66% 41%

Green 18% 48%

Amber 15% 11%

Other 1% Very slight use i.e. gardens

TOTAL 100% 100%

3.5 The Packaging Waste Regulations and Compliance Schemes

The Producer Responsibility Obligations [Packaging Waste] Regulations 1997 (as amended) mandate recovery and/or recycling targets for those companies using more than 50 tonnes of packaging per annum and whose turnover exceeds £2.0 million per year. Companies are obliged under these regulations to meet statutory recovery and recycling targets, either through their own efforts, or through joining a registered “Compliance Scheme” which then takes on the company’s legal obligations. Evidence that obligations are being met is provided in the form of Packaging Waste Recovery Notes (PRNs) or Packaging Waste Export Recovery Notes (PERNs).

Both obligated companies and compliance schemes purchase PRNs or PERNs from accredited reprocessors and exporters respectively, in order to meet their legal obligations under the Regulations. The Scheme is designed so that to the income generated from these sales will then be used to develop the necessary collection and recycling infrastructure to encourage the process.

Unarguably, these schemes have increased the amount of glass recovered from the waste stream, and they have also been instrumental in encouraging new outlets for the collected material. However, their success has not been greeted with universal approval by all sections of the established glass recycling community. Whilst some “new” glass has followed the traditional route back to the container manufacturer via the cullet reprocessors, the majority of this “new” material has been directed into the arguably less environmentally beneficial option of road making through the manufacture of aggregates; even taking account of the impact of using mined or quarried material instead of glass cullet as aggregates (Enviros 2003). This market is also not colour sensitive and it therefore removes the need for colour separation. As a consequence the Compliance Schemes have therefore tended to collect mixed glass, a material that cannot be easily reused by the primary melters. This process reduces the level of inherent benefits generated by glass recycling.

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3.6 Local Authorities

Local Authorities have a duty to collect household waste. They must collect commercial waste if asked to do so and, at their discretion, can collect industrial waste.

All waste collected by Local Authorities is collectively termed “municipal waste” and currently amounts to some 30 million tonnes each year. Since 1996/7, the amount of municipal waste collected has been growing at an annual rate of 3-4% per year. Approximately 60% of municipal waste comes from regular household collections, with a further 15% from civic amenity sites, and most of this waste goes to landfill. Local Authorities are also duty bound to prepare and publicise a waste recycling plan which details the arrangements made to recycle household and commercial waste. The Waste and Emissions Trading Act 2003 contains a provision to repeal the requirement for waste collection authorities to produce recycling plans, with the requirement being replaced by a statutory duty for local authorities in two-tier areas to have a joint strategy for the management of their municipal waste (subject to exemptions for high-performing authorities). Commencement is expected later this year, at the same time as the Statutory Instrument on the exemption from new duty is introduced.

As mentioned above Local Authorities have a duty to collect all household waste, and have statutory obligations to meet target levels of recycling. However because the target for the glass supply chain effectively goes beyond that of the local authorities and the fact that the local authorities, being in the prime position to collect glass from households, may have no incentive to go beyond their existing statutory targets, those stakeholders believe that this places a constraint on their ability to meet their targets.

Most local authorities have in place a “bring” system of recycling banks collecting such items as glass, paper, metal cans, plastics and even textiles.

Many Local Councils do recognise the limitations of these, traditional, bottle or can banks and are increasingly introducing kerbside collection schemes as a method of increasing their recycling rates.

A recent study commissioned by the Waste and Resources Action Programme (WRAP) aimed at both determining the number of kerbside collection schemes in operation, and also in quantifying the resultant increase in the volume of glass collected achieved by participation in such a scheme. The study estimated that 19% of collecting authorities were operating a kerbside collection scheme that included glass, and that these schemes gave around 10% of households, access to kerbside glass recycling.

The report concluded that:-

“If all 21.1 million UK households were offered kerbside collection then approximately 650,000 tonnes would be collected annually through kerbside schemes. Bottle bank collection would be reduced but still contribute a further 230,000 tonnes. Total glass collection would thus be estimated at 880,000 tonnes per year.”

The net consequence would be that glass collection from the domestic sector would equate to about half of the UK container production. There would, however, still remain the issue around colour discrepancy.

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The diagram below demonstrates the flow of glass through the current system.

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4 Key Drivers and Forces for/against Change

4.1 Framework

The glass sector supply chain was reviewed using the drivers and forces for change determined during the Pilot Project Launch Meeting held in October 2003 (see section 1.2 above) namely:-

• Political

• Economic

• Social

• Technological

In particular, the following forces for or against change were identified as the most relevant drivers and issues for the glass sector:-

4.2 Political

4.2.1 Legislative measures

Legislation and related issues have a huge potential to influence the activities of the glass supply chain. Significant pieces of current legislation include:-

• Integrated Pollution Prevention and Control Directive (IPPC)

• Greenhouse Gas Emissions Trading Schemes (EU and UK)

• Packaging Waste Directives

• Packaging Regulations

• End of Life Vehicle Directive (ELV)

• Waste Electrical and Electronic Equipment Directive (WEEE)

• Building Regulations

4.2.2 Fiscal measures

Similarly, environmental taxation and related fiscal measures have a huge potential to influence the activities of the glass sector supply chain, including:-

• Landfill Tax.

• Aggregates Tax.

• Climate Change Levy.

• Government grants.

4.2.3 Voluntary schemes

In some instances, industry lead initiatives can have a significant impact on sector behaviour. This can include issues such as generic product labelling or industry specific

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marketing and information campaigns. One of the longest standing in the glass sector is the ongoing Glasspac Campaign to encourage recycling

4.3 Economic

4.3.1 Process costs

Inevitably one of the key drivers for any business is the reduction and/or control of its cost base. Business is therefore continuously monitoring its costs, with a view to reducing its total unit costs in order to maximise profitability. Related to this are:

4.3.2 Process efficiency

As part of the move to drive costs out of a business, organisations are continuously striving to improve process efficiencies in terms of resource usage and the reduction of waste. Any savings made at this level have a direct impact upon the financial bottom line. The chart below demonstrates the reduction in specific energy consumption in the container sector since 1979.

4.3.3 Distribution/transport

Transport costs and the complexity of the distribution network can have a significant impact upon the profitability of a particular supply chain. In some instances the two can work in opposition for example the move to centralised packaging and bottling plants has been driven by process efficiencies and economised of scale whilst having a detrimental effect upon distances the product has to be transported to reach the market place or reuse/recycling sites.

4.3.4 Marketing issues

Issues around the marketing of consumer products and particularly fast moving consumer goods can have a significant impact upon the specification, design, manufacture and

3.18

1.471.491.86

0.0

1.0

2.0

3.0

4.0

1979 1991 1996 2003

SEC

(MW

h/to

nne)

MELTING ENERGY Container Sector – Furnace Energy Improvements 21% since 1991 - now approaching theoretical limit

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distribution of a product. One of the most significant impacts on glass packaging over recent years has been the move to single use containers and the move away from returnable/reusable containers. In parallel to this has been the drive to reduce the weight of containers, a process known as lightweighting, or producing more enclosed volume for the same mass of materials and reducing transport impacts.

4.3.5 Brand image and value

Brand has a huge value in today’s market place, and huge investment is put into maintaining the associated brand image. This factor inevitably has a huge direct impact upon the supply chain.

In the main the glass element only forms a small part of the brand offering, be it the form of a glass bottle containing the product for example, or the flat glass in the vehicle that is purchased. Consequently, in many cases the desire to maintain the brand image may work against the issues of sustainability where any attempt to improve the general sustainability of the product could potentially be seen as a threat to that brand image, be it rightly or wrongly.

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4.4 Social

4.4.1 Demands/Inertia of Society

Increasingly society is becoming more sophisticated in the demands that it places both upon itself and also upon its suppliers. Environmental and social issues are becomingly increasingly important to society at large, as has been demonstrated by the increasing requirement being placed on industry to report on non-financial aspects of business.

Inevitably, these moves are forcing business to re-examine itself and its role in society and to respond to the stakeholder pressures that are being placed upon it. Conversely, on an individual basis people are often reluctant to change, and this inertia can act against innovative ideas and forces for change.

4.4.2 Resistance to change

As mentioned, people will often demonstrate a dichotomy of approach. Whilst actively supporting new ideas and innovative solutions for society at large, they may not of themselves be prepared to change their own behaviour to embrace the approach. Equally, in many instances the costs associated with environmental degradation, or social problems, are not felt directly or perceived by the individual, and hence are not felt to be important to that individual whilst being of critical importance to society at large and for future generations to come.

4.4.3 Stakeholder perception

The perception of an organisation by its stakeholders can have an enormous impact upon the potential for success, or otherwise, of that organisation. It is quite possible for an organisation to be forced into a course of action by stakeholder pressure that it would not have otherwise taken. A typical example might be the potential impact on a Brand of the activities of a particular pressure group.

4.4.4 Investor demands

A key stakeholder group that can influence the behaviour of an enterprise is the financial community. Clearly, investors can have a major influence on the behaviour of an enterprise, with financial analysts increasingly looking at non-financial information in the determination of financial risk and the identification of investment opportunities. Also, increasingly the insurance community is also having an impact, with risk premiums being potentially reduced for organisations demonstrating responsibility to environmental and social issues, and hence a lower potential risk.

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4.5 Technological

4.5.1 Process efficiencies

Organisations are continuously seeking to improve process efficiencies in order to drive costs from the business and hence improve margins and profitability, and consequently competitive advantage. This can either be in the manner of increasing the operational efficiencies and reducing waste from existing processes or longer term it may involve the development of new and more cost effective processes.

4.5.2 New processes

The development of new process can be driven by a number of motivations, to drive costs from the business, to increase operational efficiencies and to reduce waste, to support a larger or newer product range, and to develop integrated processes or new products. The chief driver in any instance will be the achievement of competitive advantage.

4.5.3 New products

The development of new products is one of the key drivers of the market economy. A great deal of work is currently being carried out by Waste and Resources Action Programme (WRAP) to research potential new markets and products for recycled glass (see Table overleaf).

4.5.4 Intellectual property

A significant potential block to the spread of new and/or efficient technologies can be the commercial sensitivity or property rights associated with the technology which can restrict its spread to the organisations competitors.

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Table: Some potential new uses for recycled glass

Use Comments WRAP Project Ref.

Glass Filtration Media (AFM).

Dryden Aqua has successfully developed an Advanced Filtration Media (AFM) using recycled green and brown glass. This media has been put forward as potentially suitable for drinking water filtration. As such AFM is currently under review by the Drinking Water Inspectorate.

GLA2-020

ConGlassCrete. These two projects are examining the use of recovered container, plate, windscreen, lighting and fibre glass streams as alternative to both coarse and fine aggregates, and as cement replacements in the production of concrete.

GLA2-006 and

GLA15-007

The use of glass cullet in construction applications.

This research has been working to identify Best Practicable Environmental Options (BPEOs) for the use of cullet in construction.

GLA2-007

Additives for the manufacture of bricks.

This research is looking at the inclusion of up to 10% of ground glass in manufactured clay bricks, including the energy and emission reduction benefits that this could deliver on a commercial scale.

GLA2-018

Glass grit for shot blasting.

Recycled glass grit can be used as an effective abrasive media in grit blasting cleaning operations.

GLA-0013

Fluxing agent for sanitary ware.

This research is looking at the possibility of replacing current sanitary ware fluxing agents with ground recycled bottle glass, and also the potential for reducing energy requirements and emissions for manufacture.

GLA2-008

Glass derived sand for golf courses.

This research aims to assess whether ground glass would be a suitable replacement for good quality sands currently used in the sports turf industry, in particular in golf courses in root zone mixtures, bunkers and fairways.

GLA2-002

Foam glass

This project is investigating the economics, whole life costs and best practicable environmental option for introducing a UK foam glass production process. Foam Glass being an insulating material suitable for a wide range of construction applications.

GLA-0015

(Source WRAP Stakeholder Update 2003 and project reports)

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5 Benefits from the use of cullet

A significant number of environmental benefits directly accrue from the use of recycled cullet as apposed to virgin raw materials for the manufacture of glass.

5.1 Reduction of materials to landfill

Waste glass that is not destined for recycling enters the waste stream and ultimately ends up as landfill. Consequently, for every tonne of glass recycled, 1 tonne of landfill is avoided.

5.2 Avoidance of quarrying

Cullet directly substitutes virgin raw materials. As a consequence, for every tonne of cullet utilised approximately 1.2 tonne of virgin sand/limestone/dolomite/soda ash is saved, and the equivalent amount does not have to be quarried or resourced. The 0.2 tonne discrepancy is accounted for by the release of carbon dioxide during the chemical processes occurring during glass manufacture (i.e. release of CO2 from carbonate [-CO3] radicals).

5.3 Energy savings

It is estimated that the use of cullet over virgin raw materials saves the equivalent of 125kWh of energy per tonne of glass produced (i.e. approximately equivalent to the energy content of 3 gallons of oil). This energy saving arises from 3 sources:-

• Cullet melts at a lower temperature than virgin raw materials, and hence less energy is required.

• The energy of extraction/processing of the raw aggregates is eliminated.

• Energy of manufacture of the Soda Ash is likewise eliminated.

5.4 Reduction of emissions

It is estimated that for every tonne of cullet used 0.45 tonne of CO2 emissions are saved. This saving arises from 3 sources:-

• Process emissions resulting from the use of virgin raw materials (limestone/dolomite) are eliminated.

• The energy saving achieved, also represent both lower direct and indirect emissions of carbon dioxide from the use of fossil fuels.

• The energy intensive manufacture of Soda Ash is avoided.

5.5 Increase of furnace life

The running of furnaces at lower temperatures has the related effect that their service life is extended with all the associated benefits that that brings, including less frequent rebuilds.

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5.6 Associated environmental costs

The main environmental costs associated with the use of cullet centre around the energy use needed to collect, clean and process the cullet, although this is significantly offset by energy savings associated with section 5.3 above. On balance the environmental benefits associated with the use of cullet are considered to outweigh the costs.

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6 Findings

6.1 Structure of findings

The Pilot Project findings in terms of the main barriers and enablers to Sustainable Consumption and Production (SCP) are given in the Tables that follow overleaf. These findings are based on interviews carried out by the consultant with industry and supply chain representatives; they do not necessarily represent Government views. For the purposes of this report the Glass Sector Supply Chain has been broken down simplistically into the following four categories:

• Raw materials production and quarrying.

• Glass manufacture.

• Downstream customers.

• Waste stream and recycling.

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6.2 Raw materials production & quarrying

Barrier (B) or Enabler (E) Comments

6.2.1 Political B/E At present, the “Aggregates Levy” does not apply to the use of recycled glass as a substitute for quarry products used as a construction aggregate.

Whilst there is a colour imbalance in UK imports to production there may be a case for considering extending the Aggregate Levy to those colours that can beneficially be recycled back into glass production in order to encourage that recycling and reduce raw material extraction for the glass industry. The use of clear and amber glass for aggregates use could therefore attract the levy whilst green glass would not. It is recognised that alternative uses for glass of a specification and quality unsuitable for recycling to glass furnaces is beneficial.

6.2.2 Economic E The direct substitution of raw materials by cullet. Soda Ash is a major manufactured raw material used in the making of glass. The manufacturing process is very energy intensive and hence has a high potential to impact on global warming through the release of greenhouse gases (primarily carbon dioxide). Any direct substitution with cullet, therefore, has a significant environmental benefit. Conversely, this would produce a negative economic impact on the supplier of the Soda Ash through loss of market.

E The direct substitution of virgin aggregates by cullet.

Similarly to the situation with Soda Ash, the direct substitution of virgin aggregates by cullet has a significant environmental benefit (as discussed in Chapter 5 above), however, the loss of market share for the supplier has a negative economic impact on the supply chain through the quarries losing volume.

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Barrier (B) or Enabler (E) Comments

6.2.3 Social E Stakeholder pressure to reduce the impact of quarrying.

In general, the quarrying and extractive industries are coming under ever increasing criticism and pressure from stakeholder groupings, both in terms of their environmental impacts and their social performance. As a consequence, the major commercial mineral companies are looking more and more at the concept of sustainability in terms of their business operations. This work is on-going.

E A reduction of landfill opportunities. Any reduction in quarrying will de facto reduce the potential stock of future landfill sites and opportunities, with the consequential related future issues around waste disposal. The impact of raw materials substitution will, however, be relatively small in relation both to the total volumes of aggregates extracted and volumes of waste produced.

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6.3 Glass manufacture

Barrier (B) or Enabler (E) Comments

6.3.1 Political E Landfill tax encourages the use of cullet. As the costs of waste disposal to landfill increases, so the incentive to find more cost effective alternatives to it likewise increases. The benefit, in financial terms, of utilising cullet as opposed to the land-filling of waste glass, is therefore composed of two elements:-

• Firstly, the unit price to the manufacturer of purchase of the cullet itself.

• Secondly, the unit costs of putting waste glass to landfill to the waste authority.

The magnitude of the unit landfill tax can, therefore, have a potentially significant impact on this equation, and the related business decision making processes.

E Building Regulations mandate the use of low emissivity glazing systems (for both domestic and commercial building).

The most recent revision of the Building Regulation (April 2002) mandated the use of low-emissivity glazing for both new build and for the refurbishment of existing building stock, including both domestic and commercial properties. Approved Document L, which details the performance requirements for glazing systems, is due for a further review in 2005, as a direct consequence of the commitments made in the recent Energy White Paper. At present, it is unclear as to what effect, if any, this review will have upon the U-values requirements for glazing systems. The most recent review, reducing U-values to 2.0, however, had a major impact on both the glass and the glazing industries in terms of the operational processes employed.

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Barrier (B) or Enabler (E) Comments

6.3.1 Political (cont.)

B/E The Climate Change Levy acts as a disincentive to expand production of products that improve energy efficiency in wider markets , e.g.:-

• Low emissivity glass.

• Fibre glass used in the manufacture of wind farm sails.

Conversely some energy efficiency policies such as the Building Regulations increase demand for energy saving products.

Manufacturers believe that the Climate Change Levy potentially places a disincentive on the move to the manufacture of more energy intensive products in the UK.

Climate Change Agreements give an 80% reduction in the cost of the levy in return for industry meeting targets; currently most CCA targets in the glass sector are relative (SEC – specific energy consumption). Within the Agreements “relative” targets may not discourage production increases per se due to possible economies of scale. However shifts to the manufacture of products requiring more energy per unit, such as the low emissivity glass, may be discouraged, or producers must find ways of producing them that minimises the additional energy required; risk management through the use of product mix algorithms may be used to mitigate such effects until 2006.

However, other energy efficiency policies, for example higher energy efficiency requirements in building regulations substantially increase demand for these products.

A tension is felt by the glass industry between these policy tools in that they are perceived as being in direct conflict.

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Barrier (B) or Enabler (E) Comments

B/E The EU Emissions Trading Scheme (EUETS) is seen as having the same impact on the glass industry as is the Climate Change Levy.

Like the Climate Change Agreements, the EU Emissions Trading Scheme discourages the move to more energy intensive products by requiring industry to incorporate the cost of carbon into their business plans. The principle of emissions trading is to allow carbon dioxide emission reductions to be achieved at minimum cost to industry although this has yet to be demonstrated.

Stakeholders recognise that the EU ETS is intended to incentivise efficiency improvements. However, the glass industry remains fearful that the EU Emissions Trading Scheme will place an additional burden on business. Given existing technology energy efficiency improvements are limited and as such, increasing production will almost inevitably, eventually, lead to rising emissions. Consequently, some plants remain concerned that the EU ETS may damage the ability of the UK manufacturers to supply enough energy saving products from UK production to meet the government’s own Climate Change Programme.

6.3.1 Political (cont.)

B Political decision making can have a direct impact on the level of importation of glass from outside of the European Union.

It is suggested that as a direct consequence of the rising business costs associated with the implementation of EU regulations, concerning both the Environment and Climate Change within the EU, production will be and is being switched to areas outside of the EU where both the regulatory costs and human resource costs are lower. The net result is the importation of product into the EU from outside of its borders, and the related export of jobs outside of the EU. Large multi-national grouping, such as those that own many of the UK’s glass plants, are free to switch production around the globe, and in addition to which the cyclical nature of glass manufacture with major plant rebuilds ever 12-15 years encourages this possibility.

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Barrier (B) or Enabler (E) Comments

6.3.2 Economic E The move for ever decreasing u-values (for both new build and refurbishment) i.e. as required by Building Regulations and Approved Document L.

The trend for increasing the thermal efficiency of buildings, both due to the increasing costs of energy and also through the effects of global warming resulting from the combustion of fossil fuels, has had a direct impact upon the glass industry. This impact has been both in terms of the requirements placed directly on glazing systems through the Building Regulations and also through the demand for insulation products such as fibre glass. Similarly the move towards the generation of renewable energy has increased the demand for glass reinforcing fibre for the manufacture of such items as the sails for wind turbines.

E The light-weighting of glass containers is an established practice.

The light weighting of glass containers has been occurring for some time as a result of a number of drivers:-

• The drive for savings in material costs, unit production costs and hence unit price.

• The use of more technically efficient designs.

• The move to single-use packaging, which by definition does not need to be as robust as that used for re-use, and hence it can be of a lighter construction.

• The drive for the reduction in costs of transportation, i.e. simplistically, lower weight packages cost less to transport.

• The application of health and safety related issues i.e. lower weight packages are easier and hence safer to handle.

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Barrier (B) or Enabler (E) Comments

6.3.2 Economic (Cont.)

B The trend towards the greater use of single-use glass packaging.

The move to the application of single, as opposed to multiple, use glass containers has arisen for a number of distinct reasons:-

• Changes within the structure of the packer/filler industry have meant that there has been a greater centralisation of operations in order to achieve economies of scale. With the consequence that it is more difficult and costly to return a bottle for filling.

• Related to this has been a loss of the infrastructure to support a re-use industry.

• A greater emphasis is now being placed on “Brand” and the perception of the quality of the container being a reflection the brand value.

• The move towards glass container light-weighting.

• The relative wealth of society has been steadily increasing, a process that has encouraged a throw away society.

B Customer specification for products are high:-

• Container.

• Automotive.

• Flat glass.

The technical and physical performance specifications required by customers, for both flat and container glass, can be extremely demanding both in terms of colour tolerances and clarity, as well as for the physical performance of the product. It can be argued that in some circumstances these specifications could be technically relaxed in order to encourage the greater use of cullet in manufacture, and yet still maintain a high level of physical performance linked with an adequate level of colour and clarity, but within a wider tolerance band.

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Barrier (B) or Enabler (E) Comments

6.3.2 Economic (Cont.)

B The substitution of glass by plastic packaging and the impact of the Packaging Waste Directive.

Glass packaging is progressively being substituted by plastic for a number of basic container uses, such as milk and soft drinks. This is due to a number of reasons including; lightweighting, health and safety issues, shock resistance properties, as well as unit costs. It has been suggested that a consequence of the material specific recycling targets under the Packaging Waste Directive, and in particular the fact that the target for plastics is lower than that for glass, might further act as an incentive to accelerate the rate of substitution of glass by plastic containers.

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Barrier (B) or Enabler (E) Comments

6.3.3 Social E The “recyclability” of glass is seen as a significant benefit.

Glass is an infinitely recyclable commodity and one whose physical performance does not deteriorate through subsequent recycling cycles. The “recyclability” of glass is seen by the marketing community as a benefit, but equally a recycled product can be regarded by consumers as a second rate product. This aspect of marketing is of key importance and needs to be handled with care.

E Glass has a “quality” image and feel. Glass is perceived by the marketing community as having a quality feel and a quality image. For the containers of certain higher value items such as spirits and perfumes this is seen as a significant benefit enhancing the shelf appeal and brand value of the product. The solid feel and weight of the glass container is seen as a positive benefit in these circumstances.

B/E Glass packaging is seen as having a positive merchandising impact for a product in terms of shelf appeal and handling characteristics. Conversely, there are perceived to be health and safety issues associated with glass packaging as against alternative materials.

Glass packaging is perceived as bringing brand enhancement to higher value items such as spirits and perfumes. In these products the packaging forms an integral part of the product, enhancing the shelf appeal of the product. Conversely, the weight and physical performance of glass packaging (in terms of its breakability) is perceived as a negative for many lower value items, potentially presenting a greater health and safety risk to the supermarket shopper than by alternative packaging materials.

6.3.3 Social (Cont.)

B The physical weight of a container/packaging has a direct impact upon transport costs.

The physical weight of glass as a material for container manufacture has had a direct impact upon its use and the switch to plastic packaging. The unit weight of a glass container is proportionately much higher than that of an equivalent plastic container and hence the transport costs associated with the container are proportionately higher as well. For higher value goods this is not an issue but can be significant for lower value items, such as bottles of milk.

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Barrier (B) or Enabler (E) Comments

B Health and safety issues associated with the handling of waste glass are cited by some as an issue restricting the collection of the material for recycling.

The variability of the inclusion of glass in kerbside collections of materials for recycling is most often attributed to concerns over the health and safety issues associated with the handling of glass. However, it is suggested that this is no more severe than those associated with the handling of empty food cans. This perception is however a significant issue for any increase in the rate of glass recycling.

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Barrier or Enabler Comments

6.3.4 Technological

B/E Furnace efficiencies have been progressively increasing and are now reaching their technical optimum performance (see chart 1 on page 8).

The thermal efficiencies of glass furnaces, in term of energy consumption, have been improving progressively over the last 10 – 15 years, and it is now argued that they are currently at or near to their technical optimum beyond which damage to the material of the furnace will occur if insulation properties are further improved.

B/E Mixed colour cullet separation and colour enhancement technologies are available (however, they are subject to commercial restrictions and intellectual property rights).

Current local authority practice is tending to move towards the collection of mixed colour glass for recycling, whilst glass manufacture and container manufacture, in particular, require cullet to be colour separated and free from contaminants. Advanced mixed colour separation and colour enhancement technologies are becoming available for the treatment and sorting of cullet but these are proprietary processes subject to commercial restrictions and intellectual property rights which precludes their wider use and application.

B It is not currently technically possible to decolour coloured glass (green and amber primarily).

At the present time it is not technically possible to decolour coloured glass. British Glass are currently working with WRAP on a project (GLA0023) looking at the feasibility of neutralising glass colour in the furnace. The project is due to report later this year. It is felt that it will be unlikely to find a short term technical solution to this question.

B Flat glass manufacture precludes the use of post consumer cullet at present.

Due to the high quality specification of flat glass products, especially those destined for the automotive sector, only pre consumer cullet is currently used in flat glass manufacture. The key issues are the potential for contamination and the potential impact that it may have on the manufacturing process and the tight quality specification of the finished product.

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6.4 Downstream customers

Barrier (B) or Enabler (E) Comments

6.4.1 Political E The BFRC (British Fenestration Rating Council) scheme for the energy efficiency rating of windows exists but is not widely known by the general public.

A recently established, but little known rating system, exists to provide an energy rating to windows in a similar manner to that applied to white goods. The scheme rates windows on a scale of A to G on performance.

B/E It is estimated that 70% of owner occupied houses already have some form of double glazing (Palmer Market Research, 2004).

Recent research suggests that approximately 70% of owner occupied houses already have some form of double glazing. However, work carried out by BRE in 1998 suggested that a saving of 3.3 million tonnes of CO2 per annum would still be possible by installing ordinary double glazing in all of the housing stock, and that if non-domestic properties were included this could rise by a further 2.35 million tonnes. Furthermore, current estimates by British Glass suggest a saving of some 9 million tonnes could be saved per annum in the combined domestic and business stock rising to over 11 million if low emissivity glass was used. Glass and mineral wool fibre by comparison if fully incorporated could produce savings of some 39 million tonnes. The current target savings from the domestic sector in the government CCP is some 4 million tonnes.

6.4.1 Political (cont.)

B In general terms, replacement glazing is not seen as an energy efficiency measure but rather a lifestyle issue when applied to domestic housing.

According to market research, the main driver for the installation of replacement glazing is not the energy efficiency of the product. The decision is taken more usually on a need to replace basis, or as a lifestyle choice made at the point of moving into a new property. The payback period achieved through energy savings associated with replacement glazing, is perceived as being long term as opposed to similar investments such as loft insulation and cavity wall fill.

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Barrier (B) or Enabler (E) Comments

B It is estimated that approximately 6.5 million windows are replaced annually by some 8300 FENSA registered organisations (Palmer Market Research, 2004).

It is estimated that the rate of replacement of windows will progressively decline over the next few years falling to approximately 5.0 million units per annum in 2007/8. This will still create a significant waste stream, the majority of which still goes to landfill. Increasingly, first generation double glazed windows and patio doors are also being replaced, which instantly has the effect of doubling the volume of glass entering the waste stream. Consequently, the volume of waste flat glass from this source entering the waste stream is set to increase.

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Barrier (B) or Enabler (E) Comments

6.4.2 Economic E The potential may exist for a lower visual specification (i.e. in terms of colour and clarity) for the glass packaging of some supermarket own brand products.

The importance of the colour and clarity of glass containers could potentially be less for customer own brand, high volume goods. This could be particularly the case where the jar or container is covered by a printed film.

B/E The fact that a material is recyclable is said to be a stronger marketing message than the fact that a product is made from recycled raw materials.

It has been argued that the fact that a material is recyclable has a higher brand value that the fact that it is recycled. The point was made that there was evidence in another material sector that the image of a product offered in a recycled package had been diminished and that from a marketing point of view this was a significant consideration.

B Brand image and reputation are critical in many business decision making processes.

The economic value of brand can be very high indeed in today’s market place and the perception of that brand in the consumer eye can be critical to its success, or failure.

B In most circumstances, packaging has a relatively low value in terms of total product value (high value perfumes and spirits are the exception).

In many instances, the glass container forms a very low value element in proportion to the total cost of the product. Consequently, the brand managers are often very reluctant to adjust the specification of that container for a risk of a disproportionate effect upon the brand image and marketing value of the product itself. This factor is potentially less true for lower value day to day grocery items.

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Barrier (B) or Enabler (E) Comments

6.4.3 Social E Empirical evidence suggests that consumers will buy a recycled product if it costs the same, and performs as well as new virgin product.

Experience from the forest products sector suggests that, provided a product that is made from recycled materials is as technically sound, is of equivalent performance specification to, and is similarly priced then it will progressively gain a market position equivalent to a product made of virgin raw materials.

B/E Currently there is a very limited recovery of waste container glass from licensed premises, such as bars, clubs and pubs.

A recent study of licensed premises conducted in West Oxfordshire on behalf of WRAP, demonstrated that 67% of all such premises disposed of their glass waste in general waste, and that the composition of this waste varied from 10% to 90% glass content, averaging 36%. There are however limited, existing collections from pubs and clubs which could potentially be expanded.

B The return and reuse of glass packaging has all but ceased.

With the move to centralised packer fillers, the infrastructure for the return and refilling of glass bottles has all but disappeared. There is also a related perception that the risk of contamination of the finished product is greater with reused containers.

B In many instances, recycled products, and products made from recycled raw materials, are seen as being of second rate quality.

There is a widely held perception, all be it one that is changing slowly, that a product made from recycled raw materials is of lower quality than one made from virgin raw materials. Such a perception can have a strong influence on a consumers buying decision.

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Barrier (B) or Enabler (E) Comments

6.4.4 Technological

E The physical performance of recycled glass containers can be as good as for those made of virgin glass product.

The physical properties associated with recycled glass are as good as those for glass produced from virgin material, however, due to variability inherent in the use of cullet it is possible that a loss of clarity may occur and a greater variation in colour is likely i.e. the optical properties are poorer, which would impact upon the various brand owners specifications.

B The key issue for glass recycling is the colour and clarity of the finished product.

The requirements of brand owners can place very high demands on the specification of colour and clarity for glass packaging in support of their brand image. This is particularly true of high value goods such as perfumes and spirits. There is potential for discussions on the tolerances allowed for lower value goods such as customer own brand goods in jars.

B The packer fillers have concentrated capacity in fewer but larger plants in order to achieve economies of scale.

The inevitable demands of driving costs from a business, together with process efficiencies gained by economies of scale, have meant a move away from local packer fillers to regional, national or even international packing.

B There has been a gradual but inexorable move away from reusable to single use containers, as a result of:-

• Economies of scale.

• Brand image.

• Light weighting.

According to the packer/fillers this factor has been one of the most significant impacts upon the glass container sector with the move to single use containers as a consequence of the move away from local to centralised packer/fillers. The high demands of brand and brand image supported by the shelf appeal of product and the need for pristine packaging have further added to this pressure. The drive to reduce unit costs has also meant the lightweighting of packaging to allow for lower transport costs whilst maintaining the physical performance properties of the container.

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6.5 Waste stream and recycling

Barrier (B) or Enabler (E) Comments

6.5.1 Political B/E The UK Landfill Tax is amongst the lowest in Europe.

Currently, glass that is disposed of to landfill, as part of a mixed load of municipal waste, attracts the landfill tax at the standard rate of £15.00 per tonne, or the rate of £2 for inert waste where it is segregated. Despite the fact that Landfill Tax will rise by at least £3/tonne per annum from April 2005 (toward a medium term level of £35/tonne), these rates are some of the lowest in Europe and as such do not act as a specific disincentive to disposal to landfill. Conversely, cullet is being imported from Eire, where the higher rate of landfill tax together with higher gate fees renders it more cost effective to export than to dispose to landfill.

B/E There is a lack of uniform policy for the recycling of waste materials, including glass, across all UK Local Authorities.

Local waste disposal authorities are free to define their own operational policies within the constraints of the generic government imposed targets (e.g. by 2005/6 they will be expected to achieve on average a 25% composting/recycling rate for household waste). The Household Waste Recycling Act makes kerbside collection of at least 2 recyclates compulsory (with a couple of exceptions) by 2010. Weight based targets are set for Local Authorities but it is Government policy to leave it up to each Authority to decide how to meet these targets. This has, and will continue, inevitably to mean a lack of consistency and commonality of approach across the UK.

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Barrier (B) or Enabler (E) Comments

6.5.1 Political Cont.)

B/E The Packaging Waste Recovery Note (PRN) System encourages the use of recycled glass for aggregates.

The PRN System is intended to both demonstrate compliance with the requirements of the packaging Regulations and also to generate income from the sale of PRNs that will in turn be used to develop the necessary recycling infrastructure. It is not intended to act as a mechanism to drive particular methods of recovery of packaging waste. The PRN encourages the use of recyclable glass in all markets. Without it, recycling would continue in the glass container industry but probably at a lower level and glass use in aggregates would no doubt cease.

Collectors, whether companies or Local Authorities, will inevitably be mindful of pursuing the simplest and/or most cost effective path in order to meet their obligations. As long as there is a market for glass as aggregate, collection of mixed colour glass for use in the aggregates industry will be pursued. Whilst preferable to landfill some have argued that this is not the most desirable use of the available resource, although it may also be more beneficial to use glass aggregate rather than freshly quarried material.

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Barrier (B) or Enabler (E) Comments

6.5.2 Economic B The true costs of waste disposal are not born by the consumer.

Experience in other European States, such as Sweden and the Netherlands, suggests that where consumers are obliged to pay nearer the full and true costs of waste disposal directly, both the level of recycling increases and volumes of materials disposed of to landfill decreases.

6.5.3 Social E Kerbside waste recycling schemes recover greater quantities of glass than is achieved by the traditional bottle bank system.

Where studies have been carried out, it has been demonstrated that the volume of glass recovered from areas with access to kerbside collection schemes is approximately double that achieved through the traditional bottlebank system.

B/E Access to domestic kerbside waste recycling schemes is variable across the UK.

A recent report published by WRAP (June 2002) estimated that approximately 19% of waste collecting authorities were operating a kerbside collection scheme that included glass, and that these schemes gave access to 10% of all households. It concluded that if all 21.1 million households in the UK were offered kerbside collection of glass, a total of 650,000 tonnes of glass could be recovered, together with a further 230,000 tonnes through the existing bottlebank system.

6.5.3 Social (Cont.)

B The per capita density of bottle banks in the UK is one of lowest in Europe.

It is estimated that in 2002 there were some 20,796 bottlebank sites throughout England, Scotland and Wales, which equates to an average density of 1 bank per 2,860 head of population. This compares very unfavourably with our European neighbours where values of 1 per 1,000 are not uncommon.

B There are numerous public messages in the area of waste disposal, recycling and related questions, but there is no unified theme or consistency of approach.

There are an abundance of messages on the theme of the recyclability of certain materials, on recycling and on waste disposal, but there is no unified theme, message or approach. Inevitably, such an approach leads both to a dilution of the message and also confusion in the market place.

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Barrier (B) or Enabler (E) Comments

B Cultural awareness of recycling within the UK population as a whole is not widespread.

The cultural awareness of recycling and related environmental issues within UK society is not well developed, although it is improving. For example, there is public confusion over whether glass jars can be placed in bottle banks.

6.5.4 Technological

B/E The existing infrastructure for recycling is very variable around the UK.

The infrastructure required to support glass recycling is very variable around the country, mainly due to historical reasons. However with the development of MRFs (Material Recycling Facilities) it should in theory be possible to provide a much more structured approach. However, in practice this is not happening due to a number of disparate reasons including legislative, economic and social issues.

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7 Key issues

The aim of this DTI and British Glass commissioned pilot was to explore the practical application of the principles of Sustainable Consumption and Production (SCP) to the Glass Sector and Glass Supply Chain and to identify possible areas for possible future collaborative work between different stakeholders. The tables overleaf detail potential areas and key issues for action, based on discussions between the consultant and industry and supply chain representatives. They are organised into the four core categories of drivers determined by the initial project workshop. The following section (Chapter 8) develops a number of these key issues into specific project opportunities, with suggestions for further collaborative actions. The timeframes (T/F) given in the tables below are for potential actions and are given in terms of Short Term “S” (0-2 years), Medium Term “M” (3-5 years) and Long Term “L” (5 years plus). The timings are indicative only and are designed to give a rough measure of the potential complexity involved in addressing the issues raised.

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7.1 Political

Enabler Impact T/F

1 Set high environmental standards for buildings, where cost effective.

In July 2004, the Government gave the green light to a Code for Sustainable Buildings in its response to the Sustainable Buildings Task Group report 'better buildings - better lives' (published in May), in which experts from the private, public and non-governmental sectors pinpointed ways in which industry and Government can work together to promote sustainable buildings. The new Code will establish higher standards for energy and water efficiency, as well as waste and use of materials. ODPM will be leading this process with close industry and wider Government involvement and the first outline of the Code should be complete in time for the Sustainable Communities Summit in January 2005. The Code should be complete by the end of 2005, in order to take action on a national rollout by early 2006.

M

2 The active encouragement of kerbside recycling schemes and the active inclusion of waste glass in all such schemes unless its exclusion can be justified on economic, environmental or technical grounds.

Both the level of application of kerbside collection schemes for waste recycling, and the inclusion of glass in such schemes where they do exist, are very patchy. The universal application of such schemes and the inclusion of glass in all schemes would significantly increase the volume of waste glass entering the recycling chain. However unless there is colour segregation from household waste it is probable that the majority of recovered glass will go to alternative recycling schemes as opposed to use as cullet for glass manufacture.

M

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Enabler Impact T/F

3 Differentiated PRN value based on environmental credentials.

The current PRN system does not differentiate between environmentally high benefit uses of glass and very low benefit uses. The use of a differentiated system would help to increase recycling to the remanufacture with added CO2 savings.

It may be useful to consider a differentiated PRN value based on environmental credentials not withstanding the practical difficulties of implementing such a system. Whilst Government agrees that closed loop recycling of packaging glass would usually be the BPEO, it would be necessary to take into account transport distances or for that matter determine the cut off point for high vs. low values e.g. should the use of recycled glass in fibreglass manufacture or as a fluxing agent on brick manufacture be considered high value, in that both provide very significant reductions in energy and emissions together with raw material savings.

M

4 An assessment of the recovery targets assigned to the various links in the waste chain.

Supply chain stakeholders have commented that the determination of material specific waste recycling/recovery targets for Local Authorities and their alignment with Packaging Waste Recovery Targets for industry could significantly increase the volume of waste glass entering the glass recycling chain and increase the availability of cullet for recycling.

L

5 An increase of the Landfill Tax escalator (currently set at a minimum of £3 per tonne per annum from 2005).

The Landfill Tax acts as a positive disincentive for the disposal of waste materials to landfill. An increase in the escalator would have the positive effect of both discouraging the disposal of materials to landfill, and also encouraging the substitution of waste glass cullet for virgin raw materials as the relative price balance shifts in favour of the use of cullet.

L

6 A reduction in the level of VAT charged on replacement glazing.

Such a move would effectively reduce the final market price of these products within the domestic market. This in turn would act as a positive incentive to stimulate and increase the uptake of such products in the market place.

L

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Enabler Impact T/F

7 The development of a CO2 credit system for energy efficient products to assist in offsetting of carbon taxation charges.

The absolute targets for CO2 emissions required as a consequence of both the Climate Change Levy Agreements (CCA) and the European Union Emissions Trading Scheme (EUETS) are perceived by industry as placing a brake on industrial expansion, whilst making no recognition of the environmental credentials or energy saving benefits associated with the products produced. The development of such a CO2 credit mechanism could potentially encourage investment and expansion in the production of energy efficient products e.g. low emissivity glass and fibre reinforcement for the renewable energy market.

L

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7.2 Economic

Enabler Impact T/F

8 A review of the specification of glass containers with the aim of maintaining the physical performance characteristics of the packaging, whilst relaxing the optical properties specification.

The aim would be to develop a specification that enables a greater utilisation of cullet in the manufacture of container glass. In particular this would be with a view to enabling the use of a higher proportion of non-flint (coloured) glass. The main aim would be to relax the colour and clarity specification, whilst maintaining the physical performance properties, of the packaging. The key will be the initiation of a pilot project with a supermarket chain to trial a lower specification of colour and clarity of glass packaging for an own brand product or products (see Project Opportunity 1 following).

S

9 A review of waste collection mechanisms across Europe in order to establish best practice models, and identify alternative options for domestic charging for waste collection services.

The aim would be to encourage and optimise waste segregation at source, with a view to maximising recycling and recovery rates. Charging could be used as a disincentive for landfill disposal, and differential charging could be used as a mechanism to encourage segregation. A report has been published by the Strategy Unit which recommended that Local Authorities which wanted to introduce variable charging/ to provide household incentives for recycling should be enabled to do so. The Government has undertaken further work on practicalities of such schemes, and is reviewing its position.

S

10 A review of the impacts of various grant and tax break regimes upon the uptake of replacement glazing systems in both domestic and commercial properties.

The aim would be to determine and provide grants and/or fiscal incentives for the optimum encouragement of the uptake of thermal efficient glazing systems.

M

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7.3 Social

Enabler Impact T/F

11 A review of possible mechanisms for increasing the recovery of flat glass.

Currently, only a limited amount of post-consumer flat glass waste is recycled. There is a significant potential to increase this volume, and equally to increase this further by the addition of post consumer waste flat glass e.g. from the replacement window and demolition industries. The net consequences of this would be the reduction of material going to landfill, and the consequent replacement of virgin raw materials by cullet. The key will be the initiation of a pilot programme with the replacement glazing industry to investigate both the economics and practicality of flat glass recovery (see Project Opportunity 5 following).

S

12 An increase in the recovery of waste glass from licensed premises.

A significant proportion of container glass waste from licensed premises is currently disposed of to landfill. There is a significant potential for increasing the recovery rate of container glass from these sources with the related reduction in materials going to landfill, and the consequent substitution of virgin raw materials. The key will be the initiation of a pilot programme with the licensed trade to investigate both the economics and practicality of container glass recovery from these sources (see Project Opportunity 3 following).

S

13 The development and publication of “Good Practice Guides” capturing and promoting existing best practice.

The aim would be to develop a better and wider understanding of the benefits, both financial and environmental, that can be accrued from good examples of recycling of glass products. The ultimate aim will be to increase the pool of such schemes available in order to increase the volume of glass materials entering the recycling stream (see Project Opportunity 4 following).

S

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Enabler Impact T/F

14 The raising of public awareness of recycling and related issues through a national and unified TV campaign, which would need to be on-going.

Public awareness of issues around waste management and recycling is limited and patchy. Ultimately the culture of the “throw away society” has to be challenged, and the most powerful media in today’s society for widespread public communications is the television.

S

15 The related (to enabler 14) simplification of the recycling message with the use of one universal logo.

A simple message, often repeated, has been demonstrated to be more effective than a multitude of different, but similar messages.

S

16 The facilitation and encouragement of an increase in the density of Bring Banks (Bottle Banks).

By increasing access to glass banks the volume of materials collected would potentially increase, hence making more cullet available to the waste stream.

S/M

17 The initiation of educational programmes for both Key Stages 1&2, and older, pupils.

Evidence suggests that where early learning of issues around environmental and waste management is conducted, the lessons learnt will be carried forward into adult life. In addition to which, children can have a significant impact upon the behaviour of their parents.

M

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7.4 Technological

Enabler Impact T/F

18 The best environmental option is to maximise the re-use of cullet within new glass products. (Glass Recycling – Life Cycle Carbon Dioxide Emissions, Enviros Consulting, November 2003)

This report clearly demonstrates that the alternative uses of waste glass, as compared to its use as cullet for glass manufacture, all sub-optimise the environmental benefits achieved by, and associated with, the recovery and recycling process.

S

19 The encouragement of basic research with the aim of improving the technical and economic performance of the glass sector. Such research would need to be conducted on an on-going basis.

The aim would be to improve the technical and economic efficiencies of the use of glass as a material, and the more effective use of resources in its production, through areas such as :- • The development of new commercial applications and uses for recycled glass. • The development of improved technologies for the use of recycled glass e.g. colour

separation, enhancement and decolouring.

• The development of new glass packaging technologies (see Project Opportunity 2 following).

S/M

20 A review of the operation of Materials Recycling Facilities (MRFs) across UK to establish the scope for, and best practice examples of, glass recycling.

The existing infrastructure of MRFs could potentially be further developed to achieve a greater segregation of waste and higher efficiencies in the recovery of waste glass for recycling.

M

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8 Project opportunities

The tables below outline a number of specific project opportunities that have been derived from the Key Issues given in the previous section (Chapter 7). These represent specific project opportunities that offer both the potential for further investigation into the development of the principles of Sustainable Consumption and Production in the Glass Sector and its Supply Chain, and also the opportunity for the practical application of those principles.2

8.1 Project opportunity 1 (Container Glass Sector)

Project No: 001

SCP Project Area: Container Glass Sector and Recycling Sector.

Project Source: Retail Supermarket Sector.

Project overview: The project would look at the possibility of supermarket own-label products being packaged in glass containers manufactured using a high proportion of recycled glass cullet, and to a specification allowing for a higher variability in clarity and colour than the current specification allows.

8.2 Project opportunity 2 (Container Glass Sector)

Project No: 002

SCP Project Area: Container Glass Sector and Packer Filler Sector.

Project Source: Retail Supermarket Sector.

Project overview: The project would explore the concept of using ultra-violet (u/v) resistant foils and/or alternative technologies on clear glass bottles for the storage and marketing of red wine, as an alternative to utilising green glass bottles as at present.

2 All project opportunities listed in this section are either being worked on or have been undertaken by WRAP – with the exception of project no. 2, on which WRAP worked on 3 years ago.

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8.3 Project opportunity 3 (Container Glass Sector)

Project No: 003

SCP Project Area: Container Glass Sector and Recycling Sector.

Project Source: Licensed Retail Sector.

Project overview: The project would look at the feasibility of increasing glass container recovery rates from licensed premises in a small geographical area with a view to developing a model, and case study that could be applied nationally in the UK. This would include the examination and development of existing “pilot” projects.

8.4 Project opportunity 4 (Flat Glass Sector)

Project No: 004

SCP Project Area: Flat Glass Sector and Recycling Sector.

Project Source: Replacement Window Sector.

Project overview: Much good work has been done, albeit geographically restricted areas, on the recycling of glass from windows removed during the replacement of single with double glazing. This experience presents the opportunity for an excellent “Good Practice Guide” or case study. This project would investigate the work conducted, examine the possibility of developing the case study materials, and produce those materials.

8.5 Project opportunity 5 (Flat Glass Sector)

Project No: 005

Project Area: Flat Glass Sector/Recycling.

Project Source: Replacement Window Sector.

Project overview: This project is related to (Project No: 004) in that there is considerable scope for developing this approach further, to present a sound model to allow the recycling of the majority of materials removed with replacement glazing (glass, PVCu, aluminium, steel, wood etc.) with a view to reprocessing and possibly secondary manufacture at the point of recovery. This project would be a feasibility study to investigate further the opportunities for an integrated recycling, manufacturing and waste management centre.

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9 Appendices

Appendix: Title:

1 Text of the initial “Letter of Request” sent to stakeholders

2 List of stakeholders to whom the “Letter of Request” was sent

3 List of organisations that were interviewed or visited

4 Details of significant reports reviewed

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Appendix 1: Text of the initial “Letter of Request” sent to stakeholders

Dear Changing Patterns

The UK Government, via the Department of Trade and Industry and DEFRA, is looking at sustainability issues in supply chains, through its Changing Patterns Initiative. DTI/DEFRA are jointly funding, together with relevant industry bodies, a number of pilot projects looking at what sustainable consumption and production might in practice mean to industry. Three pilot sectors have been selected for this first phase; glass, construction and food. Details of the Changing Patterns Initiative and the glass sector can be found in the attached British Glass press release, and further details are available at the following web-site addresses; http://www.dti.gov.uk/sustainability/scp and http://www.defra.gov.uk/environment/business/scp/. The chief aims of these pilots are to identify the key players, barriers and enablers to sustainable consumption and production within the selected supply chains and to enter into dialogue with those players in order to develop a methodology to encourage sustainable development. The experience gained will then be used in other sector initiatives. The project will, where possible, encompass the entire life cycle of the product from raw material and energy inputs to manufacture, through production and subsequent downstream interventions, to consumer purchase and utilisation, and final disposal and recycling. In many ways, glass is an ideal material to consider in this context, being technically infinitely recyclable. The reason for our writing to you, as a key player in the glass supply chain, is to request your comments on the aims of the project, to canvass your views on the question of sustainability in the glass sector supply chain, and to ask what you see from your perspective as being the key sustainability issues, what you feel might be done practically now in the short term to encourage sustainable development, what might be done in the longer term, and what needs to be done to make it happen – particularly the last. We would be delighted to receive your comments in writing to the above address or by email to our dedicated project address at changingpatterns@britglass.co.uk, or if you prefer we would be happy to arrange a meeting with you to discuss the issues in person. Although the timescale for the project is extremely tight, we are determined to make the consultation as wide and as comprehensive as feasible, in order to produce as meaningful an outcome as possible. To that end, we have also included a list of consultees to whom this letter has been addressed, and we would be very grateful if you would spend a few minutes reviewing it, and advise us of anyone that you feel that we have omitted. I thank you for your time and look forward to receiving your comments. Yours sincerely,

David Workman Director General British Glass

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Appendix 2: List of stakeholders to whom the “Letter of Request” was sent

Allied Brewery Traders Association Midlands Glass Allied Glass Containers Ltd Morrisons Architecture Schools National Dairy Council ASDA Stores Ltd, National Federation of Glazers Automotive Glazing Executive National Joint Council for the flat glass industry Bear & Pub Association Nazeing Glassworks Beatson Clark plc Newell Ltd Bibby Sterlin Ltd NIEPA Biffa Waste Services Ltd. Onyxpak Biffpak Owens Corning Building Products Ltd Biochem (Apparatus) Ltd Pelican Public Relations BOC Ltd Philips Components Brewers and Licensed Retailers Association Pilkington Glass Ltd British Bottlers Institute Pilkington Technology Management Ltd British Glass Potters Ballotini Ltd British Institute of Inn keeping Poulten, Selfe & Lee British Retail Consortium PPG Industries (UK) Ltd British Soft Drinks Association Prof. Peter Smith, University of Leeds Building Research Establishment Public Affairs Committee Caithness Glass Quarry Products Association. Cleanapak Quinn Glass Co-op Recycling Industries Alliance Corning Rexam Glass Dairy Industry Federation RIBA Dartington Crystal Ltd RMC DEFRA Rockware Glass Ltd DTI Royal Brierley Crystal EA S Murray & Son Ltd Edinburgh Crystal Glass Co Ltd Sainsbury's Ltd, Environmental Services Association Save Waste & Prosper Escol Products Ltd Scotch Whisky Association FBG Anchor SEPA Federation of Licensed Vitlers Association SLI Glass FES SMMT Food & Drink Federation Society of Glass Technology Glass & Glazing Federation Society of Independent brewers Global Homeware Society of Licensed Vitlers Grunden Somerfield Guardian Industries St Gobain Glass UK Ltd Housing Associations Stolzle Flaconnage Industry Council for Packaging & the Environment Tarmac Recycling Institute of Brewing Tecoglass Ltd Institute of Demolition Engineers Tesco Institute of Packaging TRADA Institute of Waste Management UK Dairy Association Kingfisher United Glass Ltd Lafarge Valpak Ltd.

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Lancaster Fibre Technology Ltd Waste Watch Langham Glass Wastepak Lax & Shaw Waterford Crystal Ltd Local Authorities Wine & Spirits Association M&S WRAP

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Appendix 3: List of organisations that were interviewed or visited

Organisation or individual interviewed or visited:

Address:

1. Anglian Windows PO Box 1013 Norwich NR6 6BR

2. Berryman Lidgate Crescent South Kirkby West Yorkshire WF9 3NR

3. Bowater Windows 2 Caley Close Sweet Briar Road Norwich NR3 2BW

4. British Glass 9 Churchill Way Chapeltown Sheffield S35 2PY

5. British Retail Consortium Second Floor, 21 Dartmouth Street, London SW1H 9BP

6. Department for Environment Food and Rural Affairs (DEFRA)

Ashdown House 123 Victoria Street London SW1E 6DE

7. Department of Trade and Industry (DTI)

Sustainable Development Directorate 151 Buckingham Palace Road London SW1W 9SS

8. Food & Drinks Federation 6 Catherine Street London WC2B 5JJ

9. Future Brand Fox Court 14 Gray’s Inn Road London WC1X 8WS

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Organisation or individual interviewed or visited:

Address:

10. Glass and Glazing Federation 44-48 Borough High Street London SE1 1XB

11. Local Authority Recycling Advisory Committee (LARAC)

c/o AMEC Timothy’s Bridge Road Stratford-upon-Avon Warks. CV37 9NJ

12. Marks and Spencer plc Baker St London W1U 8EP

13. Optimat Limited James Watt Avenue Scottish Enterprise Technology Park East Kilbride Glasgow G75 0QD

14. Packaging Federation Vigilant House Suite 2.9 120 Wilton Road London SW1V 1JZ

15. Pilkington plc Group Headquarters Prescot Road St. Helens Lancashire WA10 3TT

16. PPG Industries (UK) Ltd. Fibre Glass Division Leigh Road Wigan WN2 4XZ

17. Prof. Peter Smith Emeritus Professor University of Leeds

18. Reuse Glass UK Ltd. Headlands Lane Knottingley West Yorkshire WF11 0HP

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Organisation or individual interviewed or visited:

Address:

19. Rexam Glass Barnsley Limited Monk Bretton Barnsley South Yorkshire S71 2QG

20. Rockware Glass Limited Headlands Lane Knottingley West Yorkshire WF11 0HP

21. Safeway Supermarkets Safeway Head Office 6 Millington Rd Hayes Middlesex UB3 4AY

22. Sainsbury’s Ltd. 33 Holborn London EC1N 2HT

23. Saint-Gobain Glass (UK) Ltd. Eggborough Plant Weeland Road Goole East Riding of Yorkshire DN14 0FD

24. United Glass Limited Edinburgh Way Harlow Essex CM20 2UG

25. Waitrose Doncastle Road Bracknell Berkshire RG12 8YA

26. Waste & Resources Action Programme The Old Academy 21 Horsefair Banbury Oxfordshire OX16 0AH

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Appendix 4: Details of significant reports reviewed

1. Carlton Smith, J & Roberts, C: “Glass Goes Green – a project to identify the legal and commercial barriers to glass recycling in a representative sample of licensed premises within the geographical region of West Oxfordshire – Interim Report 2”, WRAP, Banbury, December 2002.

2. DEFRA: “The Environment in your Pocket 2003”, DEFRA, London, 2003.

3. DTI/DEFRA: “Changing Patterns – UK Government Framework for Sustainable Consumption and Production”, September 2003.

4. DTI/DEFRA: “Sustainable Consumption and Production Indicators – Joint DEFRA/DTI consultation paper on a set of ‘decoupling’ indicators of sustainable development”, September 2003.

5. DTI: “Impacts of the Packaging (Essential Requirements) Regulations – A Brief Survey”, DTI, London, September 2003.

6. Entec: “Advanced Filtration Media (AFM): Clean Water Market Analysis”, WRAP, Banbury, May 2003.

7. Environmental Resources Management: “Fiscal Incentives for Sustainable Homes”, Worldwide Fund for Nature, Godalming, May 2002.

8. Enviros Consulting: “Glass Recycling – Life Cycle Carbon Dioxide Emissions”, British Glass, Sheffield, November 2003.

9. Enviros Consulting: “Recycled Glass Market Study & Standards Review – 2003 Update”, WRAP, Banbury, May 2003.

10. Enviros Consulting: “Survey of Waste Glass Collection & Recycling Arrangements in UK Local Authorities”, WRAP, Banbury, May 2003.

11. Glass Technology Services: “Kerbside collection of glass”, WRAP, Banbury, June 2002.

12. Glass Technology Services: “UK Glass Manufacture – A Mass Balance Study”, British Glass, Sheffield, October 2003.

13. Hartley, A: “The development of a methodology for recycling lamp glass, overcoming technical and practical barriers to recycling”, WRAP, June 2003.

14. Hawkins, R & Carlton Smith, J: “Glass goes green – A project to identify the legal and commercial barriers to glass recycling in a representative sample of licensed premises within the geographical region of West Oxfordshire”, WRAP, Banbury, June 2003.

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15. Hopkins, A & Foster, C: “Achieving Life Cycle Benefits through Practical Sustainable Waste Management – Opportunities, Benefits, and Barriers associated with the Use of Glass Waste as Aggregate in Coated Roadstone”, Arena Network, Pontypridd, November 2003.

16. Hurley, J: “A UK Market Survey for Foam Glass”, WRAP, Banbury, April 2003.

17. Hurley, J: “Research into waste glass, window and door frames from the demolition and replacement window industries”, WRAP, Banbury, May 2003.

18. ICER: “Materials recovery from waste cathode ray tubes (CRTs)”, WRAP, Banbury, November 2003.

19. Kent, R: “Window Rating is here”, Fenestra, London, March 2004.

20. Mineral Industry Research Organisation: “Determine Vortex Grinder Construction Materials for Glass Cullet Grinding Applications”, WRAP, Banbury, December 2003.

21. Owen, A. & Baker, S: “The use of glass-derived sands for sports areas”, WRAP, Banbury, November 2003.

22. Palmer Market Research: “The Market for Private Sector Home Improvements Vol. 2: The Window Market”, Palmer Market research, Surbiton, 2003.

23. Palmer Market Research: “The Market for Private Sector Home Improvements Vol. 3: Conservatories, Entrance and Patio Doors, Secondary Glazing”, Palmer Market research, Surbiton, 2003.

24. Pira: “Packaging in the 3rd Millennium – Competitiveness Study for the Packaging Industry in the UK”, Pira International, Undated.

25. Rexam plc: “Global Packaging Trends, Facts & Insight”, Rexam, London, 2003.

26. Rexam plc: “The Future of Consumer Packaging”, Rexam, London, 2003.

27. Shorrock, L & Pout, C: “Potential Energy Savings from the Replacement of Single Glazing by Double Glazing, High Performance Double Glazing and Advanced Glazing”, Building Research Establishment, Watford, March 1998.

28. UK Government (DEFRA lead Department), Scottish Executive, Welsh Assembly Government and the Northern Ireland Administration: “Taking It On: Developing a UK Sustainable Development Strategy Together – A Consultation Paper”, 2004.

29. WRAP: “Stakeholder Update – Glass”, WRAP, Banbury, December 2003.

30. WWF: “Building Sustainability – How to plan and construct new housing for the 21st Century”, Worldwide Fund for Nature, Godalming, October 2003.

31. WWF: “Building towards Sustainability”, Worldwide Fund for Nature, Godalming, 2003.

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British Glass

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S35 2PY Tel: +44 (0) 114 290 1850 Fax: +44 (0) 114 290 1851

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London SW1W 9SS Tel: +44(0) 20 7215 5000

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