While innovative developments in the sheet glass manufacturing process have led to increased industrial productivity and reduced costs, the economic changes and challenges that these innovations have brought are also discussed. This sheds light on the benefits of technological innovation that we are currently enjoying and the entrepreneurial spirit that has been created along the way.
Industrial technology has evolved to make manufacturing processes more efficient so that more can be produced for less. This is accomplished through technological innovations that allow parts of the manufacturing process to be combined with each other, resulting in significant cost savings. Technological innovations don’t just increase productivity; they can also change the structure of entire industries, creating new economic opportunities. For example, plate glass was a luxury item for the European aristocracy in the 17th century. It was an expensive product that only a few privileged people could afford, and it had limited uses. Today, however, it’s ubiquitous, from showcases to the exteriors of skyscrapers. This is not due to simple commoditization, but to a revolutionary change in the manufacturing process of plate glass.
In the early days of plate glass, the manufacturing process involved mixing raw materials, melting, molding, cooling, grinding, and polishing. This manufacturing method was not only isolated from each other, but also highly dependent on skilled labor, resulting in high production costs. This manufacturing method was taken for granted during the period of slow technological development, but as industrialization progressed and the need for mass production arose, it became urgent to introduce a more efficient process. The development of tank kiln technology around 1880 revolutionized the plate glass manufacturing process, which is considered the first technological breakthrough in plate glass manufacturing. By designing the tank kiln so that the raw materials for plate glass could be injected from one side and the liquid glass could be poured out the other side into a mold, the process of mixing and melting the raw materials was combined into a single process. This doubled productivity and reduced the dependence on skilled labor. This process change was of great interest not only to the glass industry at the time, but also to other manufacturing industries, and similar innovations followed in a variety of industries.
Another leap forward occurred around 1959, with the float process developed by a glassmaker named Pilkington. In this process, the molten glass from the tank kiln was passed directly over a tin bath, where it was molded into sheet glass and pushed forward until it was conveyed by rollers in a cold tunnel, where it was discharged before being cut. In this innovative process, which eliminates the need for grinding or polishing thanks to the tin bath, the raw material formulation, melting, forming, and cooling become one continuous process. This resulted in a significant increase in productivity, reducing the length of the production line by more than half, saving 80% of labor costs and 50% of energy costs. This automation and streamlining of the process has since paved the way for a wide range of glass products to be made available to the public at affordable prices.
However, attempts to increase productivity through technological innovation do not always translate directly into increased profitability. This is because the process of technological innovation often involves a sharp increase in costs or unforeseen risks. As Alastair Pilkington put it in his memoirs. “If Pilkington’s management had known in advance the total development cost of the float process, they would not have attempted the technological innovation.” Despite the immediate benefits of the float process, Pilkington’s company didn’t break even for 12 years because of the huge investment. These examples demonstrate that innovation doesn’t always guarantee a successful outcome. Nevertheless, the pursuit of continuous innovation, even at the risk of failure and loss, remains essential to the development of an industry.
As such, the path of technological innovation can be a rocky one, with the risk of overspending and failure. However, thanks to the efforts of entrepreneurs and technologists who took these risks, industrial productivity has continued to improve. We are now enjoying the benefits comfortably. We should look back at the history of technological innovation and reflect on its implications, because we believe that only those who have the ability to anticipate and properly control these risks will be able to drive the technological innovations of the future. Technological innovation is not just about creating new products or processes, but also about solving and overcoming the various challenges that arise along the way. In this way, we can make the future of our industry brighter and richer.
