Bowling Green, Ohio, Mar 18: Bowling Green State University (BGSU) researchers are leading a new initiative to integrate artificial intelligence into glass manufacturing, aiming to enhance process control and significantly improve energy efficiency.
The three-year project is part of the Northwest Ohio Glass Innovation Hub, established in 2024 to strengthen Ohio’s leadership in glass technology through collaboration between academia and industry.
The research is led by Mohammed Abouheaf, Ph.D., associate professor at BGSU’s College of Engineering and Innovation, and is supported by a $652,000 grant from the Northwest Ohio Innovation Consortium.
Advancing Smart Manufacturing with AI
“In working with our industrial partners, we have identified that energy efficiency is a significant focus in glass manufacturing,” said Abouheaf. “By integrating AI and machine learning into glass-melting processes, our goal is to improve performance and optimize energy use.”
The project aims to develop and deploy AI-driven methods that can monitor and optimize glass furnace operations in real time. One of the key challenges in glass manufacturing is the limited ability to measure internal furnace conditions, due to extreme heat and corrosive environments that restrict sensor deployment.
To overcome this, the research team will design advanced algorithms capable of estimating unmeasured variables using available sensor data, enabling more accurate and efficient process control.
Multi-Objective Optimization for Complex Systems
Unlike traditional systems that focus on a single parameter, the BGSU team is developing a multi-objective optimization framework that simultaneously balances:
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Energy efficiency
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Nitrous oxide emissions
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Operational constraints
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System robustness
This data-driven approach is expected to significantly improve manufacturing efficiency while supporting environmental sustainability.
Collaborative Innovation Across Industry and Academia
BGSU is collaborating with Actual Reality Technologies, a Toledo-based firm specializing in augmented intelligence and data modeling.
“The partnership between Bowling Green State University and Actual Reality Technologies shows how Ohio can lead the world in applying AI to manufacturing,” said Tom Bush, CEO of Actual Reality Technologies. “Together, we are creating intelligent furnaces that can learn, adapt, and optimize energy use in real time.”
The broader initiative is supported by a $31.3 million grant from the Ohio Department of Development under its Innovation Hubs program. The Glass Innovation Hub is projected to generate $25 million in state tax revenue and produce over 200 STEM graduates, addressing growing workforce demands.
Industry partners, including global leaders in glassmaking, building materials, and solar panel manufacturing, are working alongside BGSU and the University of Toledo to drive innovation in the sector.
Broader Impact Across Industries
While focused on glass manufacturing, the project’s outcomes have the potential to extend to other industries requiring high-temperature processing and advanced automation.
“Successfully integrating AI into manufacturing processes can benefit multiple industries beyond glass,” Abouheaf added. “This work is crucial as companies adapt to evolving technologies and production demands.”
