Glass Container Manufacturing

David Wendt

OI Assurance of Quality

MBAA Glass Container Manufacturing

Characteristics of Glass
Glass is a non-crystalline solid known as a vitreous, or glassy, structure. Most common materials change from a liquid to a solid at one particular temperature, their freezing (or melting) temperature. For example, water turning to ice. When cooled from melting temperatures glass gets progressively more rigid through a steady increase in its viscosity until it finally becomes solid. Viscosity is a measure of resistance to flow. Water has a low viscosity whereas cold tar has a high viscosity.

Glass Composition
Glass is made primarily of sand, soda ash and limestone Amber color is produced by adding iron, sulfur and carbon Green color is produced by adding Chrome Oxide Blue color is produced by adding Cobalt Oxide

Raw Materials
Weight Oxide Advantages Disadvantages
Inexpensive Single Component Hard to Melt Low Expansion Hard to Fine Excellent Hard to Form Durability Expensive Low Melting High Expansion Low Viscosity Poor Durability Low Expansion Good Durability Resists Devitrification High Melting High Viscosity High Viscosity Good Durability

Silica

SiO2

70%

Soda Ash Limestone Calcium Alumina

Na2 O CaO Al2 O3 Minors

15% 12% 2% 1%

Raw Materials
Cullet is recycled glass Can be used to improve furnace efficiencies Requires processing to remove contaminants
magnetic separation crushing to about 3/4 maximum size screening combined with vacuum to remove labels and aluminum caps, and non-magnetic metal separation

Processing will not remove ceramic and ovenware contamination Cost as much or more than raw materials

Batch House Location

Furnace Operation

Glass Composition, Raw Materials and Furnace Operations

Glass is a non-crystalline solid Glass is made primarily of sand, soda ash and limestone Cullet is recycled glass Adding iron, sulfur and carbon produces the amber color Amber protects product from UV radiation

Forming Process Gob To Bottle

Viscosity is a measure of how runny a liquid is Viscosity is measured in poises at a specific temperature. Water at 70 F has 1/100 poise Light oil at 70 F has 1 poise

Heavy oil at 70 F has 7 poises As glass cools, it gets stiffer or more viscous Molten glass in the forehearth at 2200F has a viscosity of 1000 poises.

Forming Process Gob To Bottle

Viscosity/Temperature Curve Log Viscosity 10 (poises) 1011 109 Increasing 107 105 103 101 Temperature Decreasing 2700 2100 1700 1100 700 1350 Viscosity Temperature Relationship 2350 2000 Temperature F Soda-Lime-Silica Glass Forming Range (I.S. Machine)
13

Annealing Point Annealing Range Softening Point

Glass Conditioning Range Melting Range

Forming Process Gob To Bottle

Diameters 3/8 to 4

What is a gob?

Lengths to 6 A gob is a specific amount of molten glass which will be formed into a glass container.

Forming Process Gob To Bottle

Weight - Vary from oz. to 48 oz. - 7 oz is typical for a 12 oz. beer bottle. Temperature - 2100 F - Uniform throughout Viscosity - consistency of thick honey - Uniform throughout

Heat Content - Typical 7 oz. gob contains 275 BTUs. - 40 gobs contain the same amount of heat as a small kerosene heater puts out in 1 hour. - We typically produce 40 gobs in 8 seconds

Forming Process Gob To Bottle

Molten glass flows by gravity from the refiner through the forehearth. In the forehearth it is carefully cooled. This controlled cooling gives it uniform temperature and a proper viscosity upon reaching the feeder.

Forming Process Gob To Bottle

Hot glass flows by gravity through a hole at the bottom of the feeder Glass flow is controlled by adjusting the tube height. Raise tube heavy flow Lower tube less flow As many as 4 gobs per cut. As many as 30 to 240 cuts per minute. 1 forehearth per I.S. machine. As many as 8 forehearths and machines per furnace

tube

Forming Process Gob To Bottle

Forehearth is constructed as a long ceramic bathtub. Glass temperature is reduced as hot glass flows through it. Typical glass is cooled from 2350 F at the entrance to 2150 F at the exit.

Refiner Entrance 2350F Temperature Glass temperature in forehearth 2150F Glass flow Exit

Forming Process Gob To Bottle

Fan air Damper block Header

Natural gas burners

Insulation Cut-away view of a forehearth Channel block

Heat from natural gas burners and cool fan air are carefully applied to the surface of the flowing hot glass. Forehearths can handle anywhere from 1 to 220 tons of glass per day depending on design.

Forming Process Gob To Bottle

Glass flow undergoes mixing action by a rotating ceramic tube.(This brings together any glass temperature differences.) Glass flow accelerated by the downward motion of the plunger Glass flow undergoes pumping action by a ceramic plunger Glass flow is sliced into gobs as it falls beneath the feeder Pumping action of plunger is timed with shearing action of shears to shape the falling gobs

Forming Process Gob To Bottle

Gob enters the delivery system at 2100 F Scoop: Routes gob to section which is ready Trough: Routes gob to proper deflector Deflector: Provides control of path of falling gob for exact alignment in center of blank. Gob delivered into the blank at 2000 F

Forming Process Gob To Bottle

Delivery equipment - Scoops in operation

Forming Process Gob To Bottle

Forming Machine

Forming Process Gob To Bottle

Glass enters the machine in the form of a gob. Forms the container through controlled cooling and shaping of the glass. The term IS stands for individual section. (This indicates the ability to take one or more sections out of production for repairs without removing the other sections from producing containers for the customer.)

Forming Process Gob To Bottle

Total time required to produce a container varies, but beer and soda bottles take approximately 10 seconds. Each section can produce 1 to 4 bottles simultaneously. Machines may have anywhere from 4 to 16 sections. Depending on container size and shape, production speed may be as fast as 700 containers per minute.

Forming Process Gob To Bottle

Typical 10 section I.S. machine Outside cavity Inside cavity Mold
1

Blank
2 3 4 5 6

Individual section

10

Cavity is a term used to indicate the location on the IS machine in which a particular container is made.

Forming Process Gob To Bottle

Typical I.S. Machine
Uses compressed air to move the mechanisms of the machine Large amounts of cooling wind is needed to cool the molds which get hot from cooling the glass. The latest generation of IS machines have computer controlled timing for various mechanism motions The older IS machines have mechanically controlled timing for the various mechanism motions

Forming Process Gob To Bottle

What is a parison?
A parison is a specifically shaped formation of glass which will be blown up like a balloon in the blow mold to form the bottle. A parison has the following features: 1. 2. 3. 4. Finish Hollow inside Non-uniform temperature Cooler skin or enamel on its outer surface 5. Temperature of 1700 F on its outer skin 6. The same amount of glass as the container it will produce

Forming Process Gob To Bottle

Formed on the blank side of an I.S. machine from the gob. Greatly differ in shape for each process A precise shape for each type of bottle Created in two seconds for a typical 7 oz. container Just barely able to hold its shape

Forming Process Gob To Bottle

Blow and Blow Process

(show animation)

Forming Process Gob To Bottle

Press and Blow Process (show animation)

Forming Process Gob To Bottle

Cooling container and transferring to machine conveyor Cooling pad Cooling pad

Forming Process Gob To Bottle

Container transfer into annealing lehr Annealing lehr

Tin spray coating application

Forming Process Gob To Bottle

Viscosity varies inversely with temperature A " GOB" is the correct shape and quantity of molten glass to make a specific container A 12 section Quad machine has 48 individual cavities There are 2 Glass Container Forming Processes Blow and Blow Press and Blow

Annealing Glass Containers

Viscosity/Temperature Curve 1013 Log Viscosity (poises) 109 Increasing 1011 Annealing Point Annealing Range Softening Point

107 105 103 101 2700 1100 700 1350 2350 2000 Temperature F Viscosity Temperature Relationship Soda-Lime-Silica Glass 2100 1700 Forming Range (I.S. Machine)

Glass Conditioning Range Melting Range

Temperature Decreasing

Annealing Glass Containers

Annealing Lehr Cross Section View
Heating zones Cooling zones

1200

Typical annealing temperature curve Annealing point

800 F 400 0

Annealing Glass Containers

What is the purpose of annealing? Relieve internal stresses in the glass. Where did the internal stresses come from? Uneven cooling of glass container during the forming process. Outer surface of the container cools fast while inner surface cools slowly.

Annealing Glass Containers

How does the lehr anneal the glass? Reheats the glass above 1050 F and holds this temperature until temperatures inside and outside the container equalize. After that, it slowly cools the container back to room temperature. How long does this reheating and slow cooling process take? Depends upon the size and shape of the container Times vary from 20 minutes to 90 minutes.

Surface Treatment of Glass Containers

Surface treatment provides lubricity Lubricity helps to

Preserve Strength Improve Bottle Handling

On our lines On the customer lines

Scratching and poor line mobility are indications of too little treatment

Surface Treatment of Glass Containers

Iridescence is an indication of too much hot-end treatment Lubricity is defined as a measure of the "slipperiness" of the bottles On bottles with hot-end and cold-end surface treatments, another measure of the effectiveness of the dual coating is called scratch resistance

Surface Treatment of Glass Containers

Non-Permanent Surface Treatments are cold-end organic coatings that after being properly applied will wash off with a water wash. Stearate, polyvinyl alcohol and sodium oleate. They are

used on bottles that are air cleaned and not washed with water prior to filling, and on returnable bottles.

Semi-Permanent Surface Treatments will not completely wash off with water. polyethylene cold-end treatment without a hot-end coating, oleic acid over a tin hot-end coating or silicone without a hotend coating. Permanent Surface Treatments will not wash off in a water rinse, pasteurization or retort process. polyethylene applied over a hot end coating. Bottles that are coated with a permanent surface treatment will be water repellent (water will bead up on the coating) on the outside sidewall.

Surface Treatment of Glass Containers

Hot End Treatment Hood

Surface Treatment of Glass Containers

Cold End Treatment Area

Surface Treatment of Glass Containers

Surface treatment provides lubricity Lubricity helps to preserve strength, improve bottle handling "Iridescence" is an indication of too much hot-end treatment Scratching and poor line mobility are indications of too little treatment.

Automatic Inspection
The purpose of inspection equipment is to increase quality and productivity by effectively removing defects and alerting operating personnel to manufacturing problems so that corrective action can be taken. Some of the major equipment vendors used today are: AMERICAN GLASS RESEARCH BARRY WEHMILLER/INEX EMHART/POWERS St. GOBAIN OWENS BROCKWAY

Automatic Inspection
Light Reflecting

Splits: Finishes, Seams Checks: Finish, Base Neck, Heel, Sidewall, Bottom Other: Lines over the Finish, Blistered Finishes, Dips in the Sealing Surface Stones Scabby Bottoms Birdswings Blisters Fused Glass

Dark/Light Defects

Automatic Inspection
Dimensional Non-Conformances

Height Diameter Out of Round Thin Spots Lean (off perpendicular) Push Up Glass Thickness

Other Inspectable Non-Conformances

Automatic Inspection
Automatic Inspection refers to the equipment that is placed on a production line to inspect container for various defects The finish is the top part of the container that is designed for the closure The finish is involved in many critical functions and has the most inspections performed on it The CID is the equipment we use to track an individual container back to the section it was manufactured on

Stress and Strength

Strength: ability to survive the loads Stress: force/area (PSI) Our Responsibility: find a design that will resist stress Design Parameters (that control stress)

Shape Glass Thickness Surface Condition Loads

Stress and Strength

Surface Condition Breaking Stress

Pristine (new) Moderate Abrasion Severe Abrasion Deep Bruises Cracks 40,000-50,000 PSI 10,000-20,000 PSI 5,000 PSI 3,000 PSI 1,000 PSI

Stress and Strength

Load
Impact Thermal Shock Internal Pressure Vertical Load Hydrodynamic Load

Description
Created when a container is contacted by another container or an object Created by rapid thermal changes: The inside surface of a cold container is heated rapidly or an outside surface is cooled rapidly Created by the product or its expansion Created when a compressive vertical force or weight is applied to the top of a container Created when the product is set in motion and the container stops

Stress and Strength

Stress and Strength

Stress and Strength

Stress and Strength

Stress and Strength

Designing the Container

Critical Nature of Design Satisfying Everyone

Customers
Consumers Brewer Container Manufacturer Brewery Warehouse Distributor/ Retail

Objectives/ Controlling Considerations Characteristics

Appeal Safety Product Integrity Quality Productivity Productivity Safety Strength Strength Cube Container Design Container Design Sealing System Container Design Container Design Filling Line Design Container Design Container Design Container Design Container Design

Designing the Container

Brewery Design Considerations
Factors Potential Issues
Surface Treatment Flavor and Character Oil Contaminants of Product UV Degradation

Efforts to Control
Keeping cold end surface treatment spray heads below the finish Maintaining clean inspection equipment Maintain light transmission within specification limits Maintaining finish dimensions Inspecting for defects that cause loss of pressure Smaller diameter sealing systems maintain pressure stresses better Maintaining proper label indents

Loss of Carbonation Sealing System

Pride in Company Name

Label Damage

Designing the Container

Brewery Design Considerations
Line Location Strength or Design Characteristic
Bulk Depalletizer Impact Strength Heel contact height

Reason for Concern

Sweep Bar

Design Features and/or Methods of Controlling

Higher heel contact height keeps impact away from higher stressed area High levels of hot end and cold end treatment Specify heavier weight tier sheets Sorting out damaged tier sheets prior to palletizing

Surface Treatment

Damage during shipment Inability to sweep bottles off of tier sheet due to tier sheet damage caused by finish in lower layer

Push up Height

Knurl Definition

Inability to sweep Specifying crescent knurls bottles off of tier sheet due to tier sheet Softening knurl definition damage

Designing the Container

Brewery Design Considerations
Line Location Strength or Design Characteristic
Decaser Finish Dimensions

Reason for Concern

Inability to pick bottles out of case Smooth flow

Design Features and/or Methods of Controlling

Match finish dimensions to decaser equipment requirements Match container diameter dimension to rail limitations Move bottom lettering to heel area Maintain body dimensions Larger bearing surface diameter can help
Gradual taper in neck area helps

Rinser

Bottle Dimensions

Inspection Capper

Bottom Plate Lettering Vertical Load

Unnecessary rejects Breakage

Bottle Dimensions

Cap pick-up

Designing the Container

Brewery Design Considerations
Line Location Strength or Design Characteristic
Filler Knurling

Reason for Concern

Sharp knurls may cause excessive wear to filling platform Filler tube breakage

Design Features and/or Methods of Controlling

Soften knurls

Finish Dimensions

Control finish dimensions and eliminate choked necks Control body dimensions for accuracy in alignment Control capacity Maintain smooth inside surface. Neck shape changes can sometime help

Bottle Dimensions

Over or under fills Turbulence while filling

Designing the Container

Brewery Design Considerations
Line Location Strength or Design Characteristic
Pasteurizer Internal Pressure Heel Contact Height

Reason for Concern

Breakage

Design Features and/or Methods of Controlling

Higher heel contact height can reduce stress at bearing surface Move area where damage may occur away from major stress points Higher push-up reduces stresses at the inside heel knuckle Lower push-up reduces stresses at bearing surface Smaller diameter reduces stresses in sidewall

Push-up Height

Bearing Surface Diameter

Designing the Container

Brewery Design Considerations
Line Location Strength or Design Characteristic
Pasteurizer
(continued)

Reason for Concern

Breakage

Design Features and/or Methods of Controlling

More glass in the lower heel and bearing surface area reduces bearing surface stresses 5-6% of nominal capacity prevents breakage due to product expansion at 0 140 F Deeper knurls prevent stress from reaching the bearing surface Decoration deeper than .012-.015 increases opportunity for checks

Glass Thickness (weight)

Headspace

Knurling

Defects

Designing the Container

Brewery Design Considerations
Line Location Strength or Design Characteristic
Labeler Impact Bottle Dimensions Surface Treatment General Line Handling Impact Strength Glass Thickness

Reason for Concern

Breakage Poor label alignment Label Adhesion

Design Features and/or Methods of Controlling

(see general line handling) Maintain body dimensions Specifying correct adhesive

Breakage and damage that may cause Increase or decrease glass breakage at another thickness depending on line location type of fracture Move center of gravity as far away as possible from shoulder contact

Center of gravity to shoulder contact height

Designing the Container

Brewery Design Considerations
Line Location Strength or Design Characteristic
General Line Handling
(continued)

Reason for Concern

Design Features and/or Methods of Controlling

Impact Strength Heel Contact Height

Bearing Surface Diameter

Breakage and damage Higher heel contact height that may cause can reduce stress at breakage at another bearing surface line location Smaller bearing surface diameter reduces stresses at bearing surface Bottles tipping Larger bearing surface diameter can help Shorten the container to reduce the height to diameter ratio

Bearing Surface Diameter Center of Gravity

Bottles tipping

Designing the Container

Brewery Design Considerations
Line Location Strength or Design Characteristic
Case Packer Bottle Dimensions

Reason for Concern

Smooth flow

Design Features and/or Methods of Controlling

Match container dimensions to lane limitations

Internal Pressure

Other Casing operations Palletizer

Bottle Dimensions

Pressure failures (see Pasteurizer-knurling) during dropping operation Packs too loose or too Maintain container tight dimensions within specifications limits Sweep bar Higher heel contact height keeps impact away from higher stressed area High levels of hot end and cold end surface treatment

Impact Strength Heel Contact Height Surface Treatment

Damage during shipment

Designing the Container

Warehouse Design Considerations

Factors
Stacking Strength Fork Lift Handling Storage at Temperatures up to 0 120 F

Potential Issues
Vertical Load Impact Internal Pressure

Efforts To Control
See Capper See General Line Handling See Pasteurizer

Designing the Container

Distributor/Retail Design Considerations Factors Potential Issues Efforts To Control
Stacking Strength Fork Lift Handling Storage at Temperatures up to 0 120 F Manual Handling Vertical Load Impact Internal Pressure See Capper See General Line Handling See Pasteurizer

Internal Pressure Impact

See Pasteurizer See General Line Handling

Fracture Analysis
Root Cause Analysis

requires that all fragments be saved consists of fracture and origin analysis to determine what type of load was applied to determine the severity of the load that caused failure reconstructing the container more pieces indicates less damage, smaller flaws and higher loads fewer pieces indicates worse damage, larger defects and smaller loads

Fracture Analysis (identifying the fracture pattern)

Fracture Analysis
Origin Analysis (identifying the stress concentrator or flaw)

evaluating the fracture pattern, once the container is reconstructed tracing surface markings back to origin

Pressure & Impact Origin

Fracture Analysis
Origin analysis (identifying the stress concentrator or flaw)

smaller mirror radii indicate less damage. Smaller flaws and higher loads large mirror radii indicate worse damage, larger defects and smaller loads Surface Markings are similar to ripples that occur when a rock is thrown into a lake; they move away from the point of entry or origin of the surface disruption. The markings on glass surfaces also move away from the origin or surface disruption

Fracture Analysis
Mirror Surface

bright shiny area immediately around the origin of the break the stress concentrator is at the center of this small area a true mirror surface is well defined and small
Origin

Dwell Mark

a single distinct mark on either side of the origin, similar to a ripple mark created when a check has been generated long before the load was applied gray (matte or lightly textured) area that surrounds the mirror surface heavier textured surface that follows the less textured surface crescent shaped marks on either side of the origin that back away from the actual origin. Apparent to the naked eye on the glass surface

Fine Hackle

Coarse Hackle

Ripple Marks

Fracture Analysis
Microscopic examination of frictive damage in the vicinity of the origin

Design, Stress & Strength, and Fracture Analysis

Glass has an inherent strength of 40,000 PSI Abrasions, bruises and checks significantly weaken container strength Glass fails only in Tension at a stress concentrator Minor design changes can have a significant effect on performance Fracture analysis leads us to the origin of glass breakage All fragments must be saved to properly identify the origin of the failure

Bottle Handling
Set single line bottle guide rails at maximum bottle diameter plus 1/8 Use nesting formula to calculate guide rail spacing for multi-wide configuration Conveyor speeds should be adjusted to within 5% of adjacent machinery speed The best stability, bottle height to diameter ratio should be no more than 4 to 1 For best handling, label panel indents should be .020 or less Wherever possible, equipment should be set up with a Lucite model of the bottle being run

Bottle Handling
Single file guide rail spacing should be set at 1/8 over maximum bottle diameter

1/8"

Bottle Handling
Multi-wide and Nesting Formula

B = D + (N-1) x 0.866D
B = Guide Rail Spacing D = Maximum Bottle Diameter N = Number of Nested Rows
Row 4 Row 3 Row 2 Row 1

Nested Pattern

Bottle Handling
Conveyor forces bottles together More clearance causes outward force Need to keep vectors straight

Bottle Handing
Types of Conveyor Controls Sensors

Photo eyes Limit switches Better overall line control Use for line changes (different bottle sizes)

PLCs

Database

Bottle Handling
Non-Metallic Parts: Guide Rail Coverings Handling Parts

Star wheels Change over parts Filling bell linings Bottle platforms Bottle uprighters

Bottle Handling

Line Location
Depalletizer Decaser

Bottle Condition
Impact Impact

Methods of Controlling
Control velocity of impact of sweep bar Maintain a smooth operation to eliminate dropping of one container on another Maintain a level transition between conveyors moving at different speeds and deadplates Use Lucite container set at maximum container diameter dimensions to set up

Conveyor Transfers

Impact

Starwheel Setups

Impact

Bottle Handling

Line Location
Accumulation Areas Filler

Bottle Condition
Impact Turbulence

Methods of Controlling
Control conveyor speeds to minimize bottle to bottle impacts Different style spreaders can help Minimizing downtime where bottles sit in pasteurizer

Pasteurizer

Internal Pressure

Maintaining internal temperatures at less than o 140 F

Bottle Handling

Line Location
Labeler Casepacking Palletizer

Bottle Condition
Surface Treatment Impact Impact

Methods of Controlling
Washing time, drying time, bottle warming and selection of adhesives Maintain operation to eliminate late drops Control velocity of impact of sweep bar

Bottle Handling

Tools: Tachometer Temperature Gun Crown Gauge Tape Measure Spread Sheet

Bottle Handling
GUIDERAIL SPACING CHART FOR NESTED BOTTLES WITH CONVEYOR SPEEDS
Customer: Location: Project No.:
* MOLD NO. * * * BPM Single File Spacing 26.66 26.66 26.66 500 700 900 2.59 2.59 2.59 0.13 0.13 0.13 0.13 4.87 4.87 4.87 103 144 185 Btls./Ft FPM B 4.60 4.60 4.60 0.00 0.00 0.00 0.00 No. of Nested Rows & Bottles/Foot @ Spacing 2 C 9.74 9.74 9.74 D 51 72 92 B 6.73 6.73 6.73 0.00 0.00 0.00 0.00 3 C 14.62 14.62 14.62 D 34 48 62 B 8.86 8.86 8.86 0.00 0.00 0.00 0.00 4 C 19.49 19.49 19.49 D 26 36 46

Capacity Diameter Btls./Sq.Ft. (Max. Dia.)

GB-16238 GB-16238 GB-16238

12 oz. 12 oz. 12 oz.

2.463 2.463 2.463

* Requires Data Input BPM = Bottles Per Minute FPM = Feet Per Minute Single File Guiderail Spacing = Max. Bottle Dia. + .125" B = Guiderail Spacing in Inches C = Bottles Per Foot of Conveyor D = Conveyor Speed in Feet Per Minute @ Spacing B 10.99 10.99 10.99 0.00 0.00 0.00 0.00

No. of Nested Rows & Bottles/Foot @ Spacing & Speed 5 C 24.36 24.36 24.36 D 21 29 37 B 17.39 17.39 17.39 0.00 0.00 0.00 0.00 8 C 38.98 38.98 38.98 D 13 18 23 B 21.66 21.66 21.66 0.00 0.00 0.00 0.00 10 C 48.72 48.72 48.72 D 10 14 18

Information contained herein constitutes proprietary confidential and trade secr et information of Owens- Illinois, Inc., and is to be accepted subject to that understanding. It is to be kept confidential and not to be copied, used, or convey

Bottle Handling
Set single-line bottle guide rails at the maximum bottle diameter plus 1/8". Use nesting formula to calculate guide rail spacing for multi-wide configuration. Conveyor speeds should be adjusted to within 5% of adjacent machinery speed. For best stability, bottle height to diameter ratio should be no more than 4 to 1. For best handling, label panel indents should be .020 or less. Wherever possible, equipment should be set up with a Lucite model of the bottle being run.

Thank You!

OI Assurance of Quality

MBAA Glass Container Manufacturing