Energy savings solutions in glass industry with VPInstruments

Energy efficiency is a top priority for manufacturers in the glass industry, where high-temperature processes drive substantial energy consumption. At VPInstruments, we help glass manufacturers gain full visibility into their compressed air and energy systems. Discover how our proven solutions enable smarter energy management, reduce waste, and lower operational costs—all while supporting your sustainability goals.

Glass packaging plants use less and less air

When you think of glass packaging, compressed air probably isn’t the first thing that comes to mind. But in reality, it plays a crucial role—without it, producing glass packaging wouldn’t be possible. In a typical glass packaging plant, the demand for compressed air can be as high as 30,000 to 35,000 normal cubic meters per hour (Nm³/h). To measure and monitor this large amount of air, a plant might use more than 20 VPInstruments flow meters. These devices help track how much air is being produced and used, making it easier to keep machines running efficiently and to quickly spot any leaks.

Glass plants can produce millions of containers each year. They rely on compressed air to power machines and to blow hot, melted glass into moulds. Like many manufacturers, glass companies are working hard to save energy—sometimes aiming to cut their use by as much as 50%. Since compressed air can account for around 30% of their total electricity use, it’s a major area for improvement. Most plants even have separate air systems—one for running the equipment and another for shaping the glass in moulds.

Glass packaging plants are amongst the largest consumers of compressed air in the world. VPInstruments is the preferred supplier of various glass manufacturers, helping them to achieve their energy savings goals.

Compressor room

Compressors in most factories are located in so called “compressor rooms”. Such compressor rooms can contain up to ten machines grouped together. There would be a number of centrifugal compressors present; for high pressure and for lower pressure. The high pressure compressors would need additional rotary screws which deliver oil-free air. Since a glass factory runs 24/7, 365 days a year and every single bottle shape needs a dedicated level of air consumption, it is obvious that a compressor management system is vital to ensure the optimum combination of compressors at all times.

Glass packaging plants are amongst the largest consumers of compressed air in the world. VPInstruments is the preferred supplier of various glass manufacturers, helping them to achieve their energy savings goals.

Flow meters compare how machines perform

By placing flow meters on each compressor and along the main air lines to the bottle-blowing machines, glass plants can closely monitor both the production and consumption of compressed air. These meters collect valuable data, which is logged alongside other utility measurements like gas, electricity, and water usage. This information gives companies a clear picture of where and how energy is used—and where it’s being wasted.

For example, comparing the amount of compressed air produced with the electricity used by a compressor helps identify how efficiently it’s running. If performance drops, the data can quickly point to problems such as a leak or a clogged filter, allowing for fast and targeted maintenance. The same data can be used to analyze how much air each machine consumes and uncover hidden inefficiencies.

Real-time insights from flow meters not only help reduce energy costs—they also raise employee awareness. When workers can see immediate changes on screen from adjustments they make to machines, they become more engaged in energy-saving efforts. Flow meters from VPInstruments can even be connected to web-based dashboards, making it easy to track performance and savings across the entire plant.