M.Sc.

(Nutraceuticals) 2011

CSP TRG AIDS

WHAT IS GLASS
SUPER COOLED LIQUID
LIQUID WHICH IS COOLED TO A STAGE WHERE ITS VISCOSITY IS SO GREAT THAT MOLECULES DO NOT MOVE FREELY ENOUGH TO FORM CRYSTALS

100% RECYCLABLE SUSTAINABLE INERT ALMOST TO EVERYTHING GOOD FOR ENVIRONMENT

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

WHAT IS GLASS
Silica Sand 68% Soda Ash 12% Limestone 10%

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

WHAT IS GLASS
CULLET
Recycled glass used at levels as high as 80% when available

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

WHAT IS GLASS
HENCE GLASS RECIPE IS

CULLET - 80%
REST 20%
SAND 70% SODA ASH 12% LIMESTONE 10% ADDITIVES 8%
M.Sc.(Nutraceuticals) 2011 CSP TRG AIDS

NEED FOR CULLET

OVER A TON OF NATURAL RESOURCES ARE SAVED FOR EVERY TON OF GLASS RECYCLED. ENERGY COSTS DROP ABOUT 2-3% FOR EVERY 10% CULLET USED IN THE MANUFACTURING PROCESS. FOR EVERY SIX TONS OF RECYCLED CONTAINER GLASS

USED, ONE TON OF CARBON DIOXIDE, A GREENHOUSE GAS, IS REDUCED. OVER AND OVER AGAIN.

GLASS HAS AN UNLIMITED LIFE, IT CAN BE RECYCLED

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

SNIPPETS ON GLASS
INORGANIC SUBSTANCE

FUSED AT HIGH TEMPERATURES & COOLED QUICKLY

PRINCIPLE COMPONENT ---SILICA (QUARTZ) INGREDIENTS OF RECIPE MAKES DIFFERENT TYPES.

MINERAL S USED TO ACHIEVE IMPROVED PROPERTIES

DECOLORIZERATION, CLARITY, COLOURING

BOROSILICATE GLASS FROM LEAD & BORON COMPOUNDS

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

MANUFACTURE
CULLET
SORTING CRUSHED TO 15 20 mm dia

SAND

OTHER RM

WASHING & SIEVING

WEIGHED MIXER FURNACE 1500 deg C

FOREHEARTH GOBS CUT OFF MOULDING COOLING

ANNEALING LEHR
PROTECTIVE COATINGS BOTTLES & JARS

SCHEMATIC DIAGRAM OF GLASS MANUFACTURING

M.Sc.(Nutraceuticals) 2011 CSP TRG AIDS

GLASS MELTING
CULLET + SAND + OTHER RM MELTED IN FURNACE (15000C) (100 TO 500 MT)

COLOUR AGENTS ADDED IN MELT OR FOREHEARTH GLASS HAS NO DISTINCT MELTING OR SOLIDIFYING TEMPERATURE DECOLORIZERS ARE ADDED TO REMOVE THE COLOUR BY MINERAL IMPURITIES

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

GOB FORMATION
GOB ONE INDIVIDUAL MASS OF MOLTEN GLASS

GOBS ---TO FORM BLANK MOLD

FURNACE DRAW-OFF ORIFICE & GOB SHEARS

ORIFICE 12 MM TO 50MM

FOR ONE CONTAINER MOLTEN GLASS FLOWS DEPENDING ON THE BOTTLE SIZE. MECHANICAL SHEARS SNIP OFF "GOBS" OF MOLTEN GLASS. EACH MAKES ONE CONTAINER. FALLING GOB IS CAUGHT BY SPOUT AND DIRECTED TO BLANK MOLDS. MASS-PRODUCTION IS MADE UP OF SEVERAL INDIVIDUAL SECTIONS, EACH IS AN INDEPENDENT UNIT HOLDING A SET OF BOTTLE-MAKING MOLDS. LARGE BOTTLES CONSISTS OF A BLANK MOLD AND A BLOW MOLD. HIGHER PRODUCTION USING DOUBLE OR TRIPLE GOBS ON ONE MACHINE. TWO OR THREE BLANK MOLDS AND SIMILAR BLOW MOLDS.

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

10

GOB FORMATION

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

11

MANUFACTURE
BLOWING THE BOTTLE OR JAR o TWO STAGE MOULDING
o
o o o BLANK MOLD FORMS NECK AND INITIAL SHAPE BLOW MOLD PRODUCE THE FINAL SHAPE BLANK MOLD COMES IN A NUMBER OF SECTIONS: FINISH SECTION CAVITY SECTION (TWO HALVES FOR PARISON REMOVAL) GUIDE OR FUNNEL FOR INSERTING GOB A SEAL FOR GOB OPENING ONCE GOB IS SETTLED IN MOLD BLOWING TUBES THROUGH THE GOB AND NECK BLOW MOLD PRODUCE FINAL SHAPE
CSP TRG AIDS

M.Sc.(Nutraceuticals) 2011

12

VIDEO CLIPS

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

13

TRANSFER & BLOW

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

14

GLASS MOULDING PROCESSES

TWO TYPES OF PROCESSES
TWO PROCESSES DIFFER ACCORDING TO THE PARISON PRODUCING.

BLOW & BLOW

NARROW MOUTH

PRESS & BLOW WIDE MOUTH

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

15

BLOW & BLOW PROCESS

GOB DROPPED INTO BLANK MOLD THROUGH A FUNNEL-SHAPED GUIDE PARISON BOTTOMER REPLACED GUIDE AIR BLOWN INTO SETTLE MOLD TO FORCE THE FINISH SECTION. AT THIS POINT THE BOTTLE FINISH IS COMPLETE.

SOLID BOTTOM PLATE REPLACED PARISON BOTTOMER AIR IS FORCED TO EXPAND THE GLASS UPWARD AND FORM THE PARISON.

PARISON REMOVED FROM THE BLANK MOLD, ROTATED TO A RIGHT-SIDE-UP

ORIENTATION FOR PLACEMENT INTO THE BLOW MOLD

AIR FORCES THE GLASS TO CONFORM TO THE SHAPE OF THE BLOW MOLD. THE BOTTLE IS COOLED TO STAND WITHOUT BECOMING DISTORTED AND IS

THEN PLACED ON CONVEYORS TO THE ANNEALING OVEN.

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

16

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

17

PRESS & BLOW PROCESS

o GOB DELIVERY AND SETTLE-BLOW STEPS ARE SIMILAR TO

BLOW-AND-BLOW FORMING.
o PARISON IS PRESSED INTO SHAPE WITH A METAL PLUNGER

RATHER THAN BLOWN INTO SHAPE

o THE FINAL BLOWING STEP IS IDENTICAL TO THE BLOW-

AND-BLOW PROCESS.
o USED FOR SMALLER NECKED CONTAINERS. o BETTER CONTROL OF GLASS DISTRIBUTION

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

18

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

19

GLASS MOULD SETS

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

20

NECK FINISH & DIMESNIONS

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

21

SCREW CAP CLOSURE DIMENSIONS

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

22

CONTAINER FINISH THREAD DIMENSIONS

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

23

DIFFERENCE IN PROCESSES
DIFFERENCE OF THE TWO PROCESSES
BLOW-AND-BLOW USED FOR NARROW-NECKED BOTTLES.

PRESS-AND-BLOW USED TO MAKE WIDE-MOUTHED JARS AND FOR INCREASINGLY SMALLER NECKED CONTAINERS. BETTER CONTROL OF GLASS DISTRIBUTION.
TYPICAL PRODUCTION RATES RANGE FROM 60 TO 300

BOTTLES PER MINUTE, DEPENDING ON THE NUMBER OF SECTIONS IN A MACHINE, THE NUMBER OF GOBS BEING EXTRUDED, AND THE SIZE OF THE CONTAINER. BLOWN BOTTLE IS REMOVED FROM THE BLOW MOLD WITH TAKEOUT TONGS AND PLACED ON A DEADPLATE TO AIR COOL FOR A FEW MOMENTS BEFORE TRANSFER TO A CONVEYOR THAT TRANSPORTS IT TO THE ANNEALING OVEN.
M.Sc.(Nutraceuticals) 2011 CSP TRG AIDS

24

ANNEALING
TO REDUCE INTERNAL STRESSES IN ANNEALING OVEN WALLS COMPARATIVELY THICK AND COOLING WILL NOT BE EVEN

INNER AND OUTER SKINS OF A GLASS BECOME RIGID

STILL-CONTRACTING INNER PORTION BUILDS INTERNAL STRESSES UNEVEN COOLING DEVELOP SUBSTANTIAL STRESSES IN GLASS BOTTLE PASSES THROUGH A LEHR FROM BLOW MOLD LEHR IS A BELT PASSING THROUGH CONTROLLED TEMPERATURE

OVEN AT A RATE OF ABOUT 200MM TO 300MM PER MINUTE

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

25

ANNEALING
GLASS TEMP IS RAISED TO 5650 C AND THEN GRADUALLY COOLED TO ROOM TEMPERATURE WITH ALL INTERNAL STRESSES REDUCED TO SAFE LEVELS IN ABOUT AN HOUR AS THEY EXIT IMPROPERLY ANNEALED BOTTLES ARE FRAGILE AND HIGH BREAKAGE HOT-FILLING ALSO PRODUCE UNACCEPTABLE BREAKAGE LEVELS.

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

26

SURFACE COATINGS
PURPOSE to reduce the coefficient of friction REASONS inner and outer surfaces have different characteristics. Outer surface comes in contact with the mold and takes the grain of the mold surface . Both surfaces are PRISTINE, MONOLITHIC, STERILE, CHEMICALLY INERT. Pristine glass has high COF, surface scratching and bruising can occur when surface rub. Surface scratching has lower breakage resistance as one cold-end coating.
M.Sc.(Nutraceuticals) 2011 CSP TRG AIDS

27

SURFACE COATINGS
METHODS Hot-end coating & Cold-end coatings Hot-end coating applied at the entrance to annealing LEHR to strength the glass surface.

Cold-end coatings depends on Filling process & end use.

Typical cold-end coatings---oleic acid, monostearates, waxes, silicones, polyethylenes The label adhesive as one cold-end coating.

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

28

INSPECTION & PACKAGING

USE MECHANICAL AND ELECTRONIC MEANS. SQUEEZE TESTERS SUBJECT THE CONTAINER WALLS TO A COMPRESSIVE FORCE ( BETWEEN TWO ROLLERS) PLUG GAUGES CHECK HEIGHT, PERPENDICULARITY, INSIDE AND OUTSIDE FINISH DIAMETERS. OPTICAL DEVICES INSPECT FOR STONES, BLISTERS, CHECKS, BIRD SWINGS, AND OTHER BLEMISHES AND IRREGULARITIES BY ROTATING THE CONTAINER PAST A BANK OF PHOTOCELLS TRANSPORTED IN REUSABLE CORRUGATED SHIPPERS. SHIPPED ON PALLETS AUTOMATIC EQUIPMENT USED TO CLEAR TIERS OFF THE PALLET AND FEED INTO THE FILLING MACHINE.

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

29

DECORATION
FROSTING ETCHING BY HYDROFLURIC ACID (HF) OR SAND BLASTING EXPENSIVE PRINTING SCREEN PRINTING INKS ARE FIRED. APPLIED CERAMIC LABEL CERAMIC FROSTING SPRAY WITH CERAMIC PAINT ( GROUND GLASS + OIL MIXTURE) FIRE OIL EVAPORATES AND GROUND GLASS FUSES ON SURFACE.
M.Sc.(Nutraceuticals) 2011 CSP TRG AIDS

30

VIDEO CLIPS

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

31

THINK
END OF LECTURE 06

M.Sc.(Nutraceuticals) 2011

CSP TRG AIDS

32