Glass in a closed loop: how research and technology are re-thinking recycling

Glass can be molten indefinite times without losing quality – a property that makes it a key material for the circularity. But the distance to cover towards genuine circular economy varies by glass segment. Read on to find out what is currently changing in research, associations and mechanical engineering – and the role Artificial Intelligence plays in this.

Returns in container glass are already functioning well in many markets. But flat glass from windows, façades and insulated glass units remain a challenge: coatings and laminations complicate separation, sorting and reclamation – and this is precisely where new solutions kick in.

Introducing the IG2Pieces system glasstec exhibitor HEGLA has developed a machine concept that enables the clean-grade separation of insulated glass into individual, undamaged components – to then reuse or recycle them in a downstream process. This concept addressed one of the central bottlenecks in flat glass recycling: the insulated glass unit. At glasstec 2024 this system was one of the exhibits in the Circular Economy area.

Further impetus comes care of research: TU Delft researches the circular use of glass along the three pillars Reduce, Reuse, Recycle. With a view to reducing material consumption the researchers study the structural topology of monolithic, structural glass components – with the aim of achieving maximum stiffness with minimum volume. TU Delft was a partner of the special show glass technology live at glasstec 2024.

Not only enterprises and research institutions are dealing with this topic – change is also driven by associations.

The Bundesverband Flachglas e. V. (BF) (German Flat Glass Manufacturers’ Association) has undertaken a joint analysis with ift Rosenheim and the Fraunhofer Institute for Silicate Research (ISC) of the state of affairs in Flat glass recycling in Germany. The result is sobering: of the approx. 521,000 tons of flat glass cullet available only 19% return to float glass melting tanks as high-quality cullet. The larger share ends up in container glass or in glass wool – a downcycling that does not do justice to the potential this material holds. This analysis shows: the circular economy requires not only new technologies but also changed structures and a new awareness along the entire recycling chain.

longside machine technology Artificial Intelligence is gaining importance in glass recycling – in two key fields of application. Firstly, data-controlled systems analyse operational data and provide plant operators with targeted recommendations to act: for process control, for improving plant efficiency and for planning maintenance jobs. Secondly, AI is increasingly used in sensor-based sorting systems, which scan and analyse all material streams – thereby ensuring a more efficient separation and processing of glass.

Circular economy will again feature as one of the three Hot Topics at glasstec 2026 from 20 to 23 October in Düsseldorf – and the aforementioned examples show why: technology, research and associations jointly create the basis for a glass industry that consistently keeps resources in a closed loop.