01 Wendt Glass Bottle 2007

OI – Assurance of Quality MBAA Glass Container Manufacturing

Glass Container Manufacturing

David Wendt

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 limestoneAmber color is produced by adding iron, sulfur and carbonGreen color is produced by adding Chrome OxideBlue color is produced by adding Cobalt Oxide

Silica

Soda Ash

Limestone Calcium

Alumina

Weight Oxide Advantages Disadvantages

SiO2 70%

InexpensiveSingle ComponentLow ExpansionExcellentDurability

Hard to MeltHard to FineHard to Form

Na2O 15% Low MeltingLow Viscosity

ExpensiveHigh ExpansionPoor Durability

CaO 12% Low ExpansionGood Durability

High MeltingHigh Viscosity

Al2O3 2% ResistsDevitrification

High ViscosityGood Durability

Minors 1%

Raw Materials

Cullet is recycled glassCan be used to improve furnace efficienciesRequires 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

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

Water at 70 ºF has 1/100 poise

Light oil at 70 ºF has 1 poise

Viscosity is a measure of how runny a liquid isViscosity is measured in poises at a specific temperature.

As glass cools, it gets stiffer or more viscous

Heavy oil at 70 ºF has 7 poises

Molten glass in the forehearth at 2200ºF has a viscosity of 1000 poises.

Forming Process – Gob To Bottle

Melting RangeGlass Conditioning Range

Forming Range(I.S. Machine)

Annealing Range

2700 2100 1700 1100 700

2350 2000 1350

1013

1011

109

107

105

103

101

Viscosity/Temperature Curve

Log Viscosity(poises)

Increasing

Viscosity Temperature RelationshipSoda-Lime-Silica GlassTemperature ºF

TemperatureDecreasing

Annealing Point

Softening Point


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

What is a gob?

Diameters 3/8” to 4”

Lengths ½” to 6”


- Vary from ½ oz. to 48 oz.

- 7 oz is typical for a 12 oz. beer bottle.

Weight- 2100 ºF- Uniform

throughout

Temperature Viscosity- consistency of

thick honey- Uniform

throughout


Heat Content- Typical 7 oz. gob contains 275 BTU’s.- 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

• 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.


Hot glass flows by gravity through a hole at the bottom of the feederGlass flow is controlled by adjusting the tube height.Raise tube heavy flowLower 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


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

at the exit.

Refiner

Entrance ExitGlass flow

Glass temperature in forehearth

Temperature

2350ºF

2150ºF


• Heat from natural gas burners and cool fan air are carefully applied to the surface of the flowing hot glass.

Fan air

Damper block

InsulationChannel block

Natural gas burners

Header

Cut-away view of a forehearth

• Forehearths can handle anywhere from 1 to 220 tons of glass per day depending on design.


• 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


Gob enters the delivery system at 2100 ºF

Scoop:Routes gob to section which is ready

Trough:Routes gob to proper deflector

Gob delivered into the blank at 2000 ºF

Deflector:Provides control of path of falling gob for exact alignment in center of blank.


Delivery equipment - Scoops in operation



Forming Machine

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.)


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.


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

Inside cavityOutside cavity

MoldBlank

Individual section

12

34

56

78

910


Typical 10 section 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


Typical I.S. Machine

1. Finish2. Hollow inside3. Non-uniform temperature4. Cooler skin or enamel on its outer

surface5. Temperature of 1700 F on its outer skin6. The same amount of glass as the

container it will produce

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:


What is a parison?

Formed on the blank side of an I.S. machine from the gob.

Greatly differ in shape for each processA precise shape for each type of bottleCreated in two seconds for a typical 7 oz. containerJust barely able to hold its shape


Blow and Blow Process

(show animation)


Press and Blow Process

(show animation)


Cooling pad

Cooling pad


Cooling container and transferring to machine conveyor

Tin spray coating application

Annealing lehr


Container transfer into annealing lehr

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


Melting RangeGlass Conditioning Range

Forming Range(I.S. Machine)

Annealing Range

2700 2100 1700 1100 700

2350 2000 1350

Viscosity/Temperature Curve

Log Viscosity(poises)

Increasing

Viscosity Temperature RelationshipSoda-Lime-Silica Glass

Temperature ºF

TemperatureDecreasing

Annealing Point

Softening Point

1013

1011

109

107

105

103

101

Annealing Glass Containers

Heating zones Cooling zones

Typical annealing temperature curve

800

400

0

ºF

1200Annealing point


Annealing Lehr Cross Section View

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.


How does the lehr anneal the glass?• Reheats the glass above 1050 ºF 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 lubricityLubricity 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


“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

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 hot-end 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.



Hot End Treatment Hood


Cold End Treatment Area

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.


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 SurfaceDark/Light Defects• Stones• Scabby Bottoms• Birdswings• Blisters• Fused Glass


Dimensional Non-Conformances• Height• Diameter• Out of Round• Thin Spots• Lean (off perpendicular)• Push Up

Other Inspectable Non-Conformances• Glass Thickness


“Automatic Inspection” refers to the equipment that is placed on a production line to inspect container for various defectsThe finish is the top part of the container that is designed for the closureThe finish is involved in many critical functions and has the most inspections performed on itThe 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 loadsStress: force/area (PSI)Our Responsibility: find a design that will resist stressDesign Parameters (that control stress)• Shape• Glass Thickness• Surface Condition• Loads

Stress and Strength

Surface Condition Breaking StressPristine (new) 40,000-50,000 PSI

Moderate Abrasion 10,000-20,000 PSI

Severe Abrasion 5,000 PSI

Deep Bruises 3,000 PSI

Cracks 1,000 PSI

Stress and Strength

Load DescriptionImpact Created when a container is contacted

by another container or an object

Thermal ShockCreated by rapid thermal changes:The inside surface of a cold container isheated rapidly or an outside surface is

cooled rapidly

Internal Pressure Created by the product or its’ expansion

Vertical LoadCreated when a compressive verticalforce or weight is applied to the top of a

container

Hydrodynamic Load Created when the product is set inmotion and the container stops

Stress and Strength

Customers Objectives/Considerations

ControllingCharacteristics

Consumers AppealSafety

Container DesignContainer Design

Brewer Product Integrity Sealing System

ContainerManufacturer

QualityProductivity


Brewery ProductivitySafety

Filling Line DesignContainer Design

Warehouse Strength Container Design

Distributor/Retail

StrengthCube


Designing the ContainerCritical Nature of Design – Satisfying Everyone

Factors Potential Issues Efforts to Control

Flavor and Characterof Product

Surface Treatment

Oil Contaminants

UV Degradation

Keeping cold end surface treatmentspray heads below the finishMaintaining clean inspectionequipmentMaintain light transmission withinspecification limits

Loss of Carbonation Sealing System

Maintaining finish dimensionsInspecting for defects that causeloss of pressureSmaller diameter sealing systemsmaintain pressure stresses better

Pride in CompanyName Label Damage Maintaining proper label indents

Designing the ContainerBrewery Design Considerations

Line Location Strength or DesignCharacteristic

Reason forConcern

Design Features and/orMethods of Controlling

Bulk Depalletizer Impact StrengthHeel contact height

Surface Treatment

Push up Height

Knurl Definition

Sweep Bar

Damage duringshipment

Inability to sweepbottles off of tiersheet due to tier sheetdamage caused byfinish in lower layer

Inability to sweepbottles off of tiersheet due to tier sheetdamage

Higher heel contact heightkeeps impact away fromhigher stressed area

High levels of hot end andcold end treatment

Specify heavier weighttier sheets

Sorting out damaged tiersheets prior to palletizing

Specifying crescent knurls

Softening knurl definition



Reason forConcern


Decaser Finish Dimensions Inability to “pick”bottles out of case

Match finish dimensionsto decaser equipmentrequirements

Rinser Bottle Dimensions Smooth flow Match container diameterdimension to raillimitations

Inspection Bottom PlateLettering

Unnecessary rejects Move bottom lettering toheel area

Capper Vertical Load

Bottle Dimensions

Breakage

Cap pick-up

Maintain body dimensionsLarger bearing surfacediameter can help

Gradual taper in neck areahelps



Reason forConcern


Filler Knurling

Finish Dimensions

Bottle Dimensions

Sharp knurls maycause excessive wearto filling platform

Filler tube breakage

Over or under fills

Turbulence whilefilling

Soften knurls

Control finish dimensionsand eliminate chokednecksControl body dimensionsfor accuracy in alignment

Control capacity

Maintain smooth insidesurface. Neck shapechanges can sometimehelp



Reason forConcern


Pasteurizer Internal PressureHeel Contact Height

Push-up Height

Bearing SurfaceDiameter

Breakage Higher heel contact heightcan reduce stress atbearing surfaceMove area where damagemay occur away frommajor stress points

Higher push-up reducesstresses at the inside heelknuckleLower push-up reducesstresses at bearing surface

Smaller diameter reducesstresses in sidewall



Reason forConcern


Pasteurizer(continued)

Glass Thickness(weight)

Headspace

Knurling

Defects

Breakage More glass in the lowerheel and bearing surfacearea reduces bearingsurface stresses

5-6% of nominal capacityprevents breakage due toproduct expansion at1400F

Deeper knurls preventstress from reaching thebearing surface

Decoration deeper than.012-.015” increasesopportunity for checks



Reason forConcern


Labeler Impact

Bottle Dimensions

Surface Treatment

Breakage

Poor label alignment

Label Adhesion

(see general line handling)

Maintain body dimensions

Specifying correctadhesive

General LineHandling

Impact StrengthGlass Thickness

Center of gravity toshoulder contactheight

Breakage and damagethat may causebreakage at anotherline location

Increase or decrease glassthickness depending ontype of fracture

Move center of gravity asfar away as possible fromshoulder contact



Reason forConcern


General LineHandling(continued)

Impact StrengthHeel Contact Height



Center of Gravity

Breakage and damagethat may causebreakage at anotherline location

Bottles tipping

Bottles tipping

Higher heel contact heightcan reduce stress atbearing surface

Smaller bearing surfacediameter reduces stressesat bearing surface

Larger bearing surfacediameter can help

Shorten the container toreduce the height todiameter ratio



Reason forConcern


Case Packer Bottle Dimensions

Internal Pressure

Smooth flow

Pressure failuresduring droppingoperation

Match containerdimensions to lanelimitations

(see Pasteurizer-knurling)

Other Casingoperations

Bottle Dimensions Packs too loose or tootight

Maintain containerdimensions withinspecifications limits

Palletizer Impact StrengthHeel ContactHeight

Surface Treatment

Sweep bar

Damage duringshipment

Higher heel contact heightkeeps impact away fromhigher stressed area

High levels of hot end andcold end surface treatment


Factors Potential Issues Efforts To ControlStacking Strength Vertical Load See CapperFork Lift Handling Impact See General Line

HandlingStorage atTemperatures up to1200F

Internal Pressure See Pasteurizer

Designing the ContainerWarehouse Design Considerations

Factors Potential Issues Efforts To ControlStacking Strength Vertical Load See CapperFork Lift Handling Impact See General Line

HandlingStorage atTemperatures up to1200F

Internal Pressure See Pasteurizer

Manual Handling Internal Pressure

Impact

See Pasteurizer

See General LineHandling

Designing the ContainerDistributor/Retail Design Considerations

Root Cause Analysis• requires that all fragments be saved• consists of fracture and origin analysis

Fracture Analysis (identifying the fracture pattern)• 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

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

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

Fine Hackle• gray (matte or lightly textured) area that surrounds the mirror surface

Coarse Hackle• heavier textured surface that follows the less textured surface

Ripple Marks• 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

Origin

Fracture Analysis

Microscopic examination of frictive damage in the vicinity of the origin

Fracture Analysis

Glass has an inherent strength of 40,000 PSIAbrasions, bruises and checks significantly weaken container strengthGlass fails only in Tension at a stress concentratorMinor design changes can have a significant effect on performanceFracture analysis leads us to the origin of glass breakageAll fragments must be saved to properly identify the origin of the failure

Design, Stress & Strength, and Fracture Analysis

Set single line bottle guide rails at maximum bottle diameter plus 1/8” Use nesting formula to calculate guide rail spacing for multi-wide configurationConveyor speeds should be adjusted to within 5% of adjacent machinery speedThe best stability, bottle height to diameter ratio should be no more than 4 to 1For best handling, label panel indents should be .020” or lessWherever 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 = Guide Rail Spacing

D = Maximum Bottle Diameter

N = Number of Nested Rows Row 4

Row 3

Row 2

Row 1

Nested Pattern

Bottle Handling

B = D + (N-1) x 0.866D

Conveyor forces bottles togetherMore clearance causes outward forceNeed to keep vectors straight

Bottle Handling

Types of Conveyor ControlsSensors• Photo eyes• Limit switches

PLC’s• Better overall line control

Database• Use for line changes (different bottle sizes)

Bottle Handing

Non-Metallic Parts:Guide Rail CoveringsHandling Parts• Star wheels• Change over parts• Filling bell linings• Bottle platforms• Bottle uprighters

Bottle Handling

Line Location Bottle Condition Methods of Controlling

Depalletizer ImpactControl velocity of impact ofsweep bar

Decaser ImpactMaintain a smooth operationto eliminate dropping of onecontainer on another

Conveyor Transfers Impact

Maintain a level transitionbetween conveyors movingat different speeds anddeadplates

Starwheel Setups ImpactUse Lucite container set atmaximum container diameterdimensions to set up

Bottle Handling


AccumulationAreas Impact

Control conveyor speeds tominimize bottle to bottleimpacts

Filler TurbulenceDifferent style spreaders canhelp

Pasteurizer Internal Pressure

Minimizing downtime wherebottles sit in pasteurizer

Maintaining internaltemperatures at less than140oF

Bottle Handling


Labeler Surface TreatmentWashing time, drying time,bottle warming and selectionof adhesives

Casepacking ImpactMaintain operation toeliminate late drops

Palletizer ImpactControl velocity of impact ofsweep bar

Bottle Handling

Tools:TachometerTemperature GunCrown GaugeTape MeasureSpread Sheet

Bottle Handling

GUIDERAIL SPACING CHART FOR NESTED BOTTLES

WITH CONVEYOR SPEEDS

Customer:Location:

Project No.:

* * * * No. of Nested Rows & Bottles/Foot @ Spacing

MOLD NO. Capacity Diameter Btls./Sq.Ft. BPM Single File Btls./Ft FPM 2 3 4(Max. Dia.) Spacing B C D B C D B C D

GB-16238 12 oz. 2.463 26.66 500 2.59 4.87 103 4.60 9.74 51 6.73 14.62 34 8.86 19.49 26

GB-16238 12 oz. 2.463 26.66 700 2.59 4.87 144 4.60 9.74 72 6.73 14.62 48 8.86 19.49 36

GB-16238 12 oz. 2.463 26.66 900 2.59 4.87 185 4.60 9.74 92 6.73 14.62 62 8.86 19.49 46

0.13 0.00 0.00 0.00

0.13 0.00 0.00 0.00

0.13 0.00 0.00 0.00

0.13 0.00 0.00 0.00

* Requires Data Input No. of Nested Rows & Bottles/Foot @ Spacing & Speed

BPM = Bottles Per Minute 5 8 10

FPM = Feet Per Minute B C D B C D B C D

Single File Guiderail Spacing = Max. Bottle Dia. + .125" 10.99 24.36 21 17.39 38.98 13 21.66 48.72 10

B = Guiderail Spacing in Inches 10.99 24.36 29 17.39 38.98 18 21.66 48.72 14

C = Bottles Per Foot of Conveyor 10.99 24.36 37 17.39 38.98 23 21.66 48.72 18

D = Conveyor Speed in Feet Per Minute @ Spacing 0.00 0.00 0.00

0.00 0.00 0.00

0.00 0.00 0.00

0.00 0.00 0.00

Information contained herein constitutes proprietary confidential and trade secret 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.

Bottle Handling

OI – Assurance of Quality MBAA Glass Container Manufacturing

Thank You!

01 Wendt Glass Bottle 2007

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