Interview: The AI-optimised and data-controlled future of recycling

Thomas Wesian's business focuses on shaping the future of the glass industry, specifically by leveraging AI and data to promote a more effective circular economy. In a recent discussion, he shared insights on the various topics, opportunities, and challenges involved in this endeavor.

In your talk at glasstec 2024 you spoke about AI-optimised glass recycling. Which concrete AI applications do you currently see in this industry and which potentials are still untapped?

Thomas Wesian: “Artificial Intelligence (AI) – like in many areas of living and working – has also gained in importance in industrial glass recycling. Possible applications are wide and varied and the actual potential is only gradually being recognised and exploited.
At present, two central applications of AI in glass recycling can be identified. On the one hand, data-controlled recommendations, based on previously collected operating data, provide valuable insights. AI helps to analyse this data to support machine and plant operators in daily operations with targeted and data-based recommendations. This can include process control, improvement of plant efficiency or the precise scheduling of maintenance jobs.

On the other hand, AI is used more and more widely in sensor-based sorting devices that scan and classify each individual part that is running through a recycling plant. This not only means important conclusions can be drawn about the properties of the material flow but also that challenges can be met which had until now proven tricky. One example is the maximisation of throughput by more efficient sorting and processing of glass. AI will also make it possible to identify dark cullet, which will in future no longer end up in CSP (ceramic, stone, porcelain) waste but can be reclaimed as valuable glass from the recycling process.

The integration of AI into these processes holds enormous potential for further increasing efficiency and sustainability in glass recycling. This means these technologies make an important contribution to the development of a circular glass economy.”

Which opportunities and challenges do you see in the implementation of a circular glass economy?

Thomas Wesian: “The implementation of a circular glass economy offers substantial opportunities but also brings challenges. In terms of opportunities there is enormous potential for saving valuable resources and markedly reducing energy consumption as well as CO₂ emissions. Glass can be recycled almost infinitely. Maximum integration of recycled glass into production cycles could reduce raw material consumption noticeably and lay the foundation for a sustainable and resource-saving economy.

In addition, a circular glass economy brings economic benefits since it reduces the dependence on raw material imports and provides energy gains via new technologies such as AI-assisted sorting. At the same time, it strengthens the sector’s innovative power by linking digitalisation with circularity.

The key challenges include the collection and sorting of waste glass whose quality and purity decisively impact its reuse. Efficient collection structures and modern sorting technologies are of vital importance here. Likewise, glass properties and design play an ever more important role. Trends such as varnish coatings or prints on glass substantially impair its recyclability and prove more and more challenging.
Beyond this, the transition to a circular glass economy requires sizeable investment in infrastructure as well as close cooperation between business, politics and science. Consistent standards and a legal framework are needed to provide the necessary incentives and promote international cooperation.

But despite all this, the opportunities outweigh the challenges. A circular glass economy is not only key to ecological sustainability but also to the glass industry’s long-term competitiveness. It makes a major contribution to coping with such global challenges as climate change and scarce resources.”

How does the implementation of a circular glass economy in Europe differ from other regions or international approaches?

Thomas Wesian: “The implementation of a circular glass economy in Europe is different because of a combination of regulatory, economic and infrastructural factors that do not exist to the same extent in many other regions. Europe invested in a comprehensive recycling infrastructure early on and introduced large-scale collection schemes which make for high collection rates. Consistent standards include unambiguous provisions and promote the efficient and high-quality reuse of glass.

Another central driver is the widespread use of cullet in new container glass production. In Europe this is strongly promoted not only by the benefits associated with resource savings but also by the comparatively high energy prices, since the processing of recycled glass requires less energy than the production of primary raw materials.

A fundamental difference versus other regions is also the land-fill ban for glass, which applies in numerous regions of Europe. While in other parts of the world glass is often disposed of on landfills, this ban forces glass to be returned into the recycling loop in Europe.
By comparison, many regions lack a comparable legal framework, technical standards and cross-regional infrastructure. This all makes the recycling rate markedly lower there. Europe, by contrast, combines technological innovations, economic incentives and political measures to drive the circular glass economy, serving as a role model worldwide.”

Glass is often called an ideal material for the circular economy. What might this sector learn from other industries – also in terms of AI use – and how can it continue to strengthen its pioneering role?

Thomas Wesian: “The glass industry can learn from some other sectors how AI is selectively used for process optimisation, preventive maintenance and data-based decision-making. Here, not only does the effective use of data play a pivotal role but also the linking of knowledge and experiences across the entire value chain. Different manufacturers, players and experts must pool their know-how and innovative power to jointly develop new approaches and technologies.

In particular, open exchange on data and best practices such as recycling processes or design concepts, for instance, can take the industry to the next level. Only if each player makes a contribution and solutions are worked out jointly can the potential of the circular glass economy be fully exploited. This allows the glass industry to further strengthen its pioneering role and shape an even more sustainable future.”