Glass Futures and the University of Liverpool's VEC (Virtual Engineering Centre) are launching AI Glass, a digital twin project designed to accelerate decarbonisation and drive innovation in the glass manufacturing industry. This collaboration represents a major step in sustainable manufacturing and industry digitalisation.

As part of a wider £1.5m project funded by UKRI, the AI-GLASS project will help industry partners accelerate decarbonisation efforts, improve efficiency and confidently adopt new low-carbon fuels and materials.

Located at Glass Futures' 165,000 sq. ft Global Centre of Excellence in St Helens, the project builds on the centre's pilot furnace and research labs. AI-GLASS will deliver a virtual replica of the glass manufacturing process, integrating advanced physics modelling and artificial intelligence for sustainable technology development.

The digital environment will empower manufacturers to experiment with specific variables in the process, such as transitioning to hydrogen or biofuels, and adjusting batch compositions without disrupting production or risking equipment. The system can instantly predict the impact on energy use, emissions, melt quality, and operating costs, enabling fast, evidence-based decision-making.

AI-GLASS also features an immersive 3D digital twin of the entire Glass Futures site, crafted through a combination of BIM data, LiDAR scanning, and UAV photogrammetry. This photorealistic model will be instrumental in training, safety planning, remote walkthroughs, and visualising live process insights.

AI-GLASS offers the tools necessary for exploring cleaner technologies like hydrogen firing and electrification safely and swiftly.

Dr Konstantin Vikhorev, Chief Technology Officer at the VEC, emphasised, "AI Glass will revolutionise how the industry approaches decarbonisation. By merging advanced modelling and AI, we can help manufacturers explore new fuels and materials in seconds, reducing risk and accelerating progress toward sustainable, efficient and cleaner glass production."

Justin Kelly, CEO of Glass Futures added, "Working with the VEC on AI Glass shows the power of collaboration in tackling global challenges. By combining digital twin technology with AI, we're creating a virtual environment that accelerates decarbonisation and gives manufacturers the confidence to innovate without risk—optimising processes, improving efficiency, and cutting costs while maintaining quality and sustainability. This is innovation with impact."

AI-GLASS marks a significant leap forward for sustainable manufacturing, enhancing the UK's leadership in industrial digitalisation and clean technology innovation. By offering real-time, data-driven decision platforms, the project supports Glass Futures' mission to lead the global transition to environmentally responsible materials production.

This project builds on the Centre's previous research demonstrating that sustainable biofuels can reduce carbon emissions by up to 80% compared with high carbon natural gas, further promoting sustainability through advanced testing and technology development.

For more information, please contact:
vec@liverpool.ac.uk

Published: 04-12-2025