MANUFACTURING OF GLASS BOTTLE: 3 CRUCIAL ...

Have you ever wondered how Glass bottles and Glass jar manufacturing takes place?

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In today's blog, you will find the answers to all your questions related to the production of glass bottles and jars.

Modern glass container production comprises three main stages:

• The Batch House stage – handling of raw materials.
• The Hot End stage – involving the manufacturing and moulding process including forehearth, forming machines, and annealing ovens.
• The Cold End stage – focuses on product inspection and packaging.

Let’s dive deeper into these three stages.

Batch House Stage in Glass Bottle Production

Stage 1: Gathering Raw Materials

Natural raw materials are integral to the production of glass bottles and jars. The primary materials include silica and soda lime. Soda lowers the melting point of sand, and lime ensures the glass is hard, shiny, and durable. Cullet, or recycled broken glass, is sourced from rejected bottles, recycling points, bottle banks, and kerbside collections. This recycled glass is vital in manufacturing glass containers.

Stage 2: Batch Preparation

The materials are finely ground using a grinding machine. This includes raw materials, cullet, and decolourisers or colourisers. The ingredients are then precisely weighed and mixed until they form a homogenous mixture known as a batch or frit. This batch is stored in large vertical siloes before being fed into the furnace.

Hot End Stage in Glass Bottle Production

Glass Bottles

Stage 3: Melting in the Furnace

The batch is melted in a furnace at around 1748°C, operating continuously with a lifespan of approximately 10-12 years. The molten glass then flows through forehearths, which regulate its passage into forming machines.

Stage 4: Glass Forming

There are two primary methods to form glass bottles: Blow & Blow (B&B) and Narrow Neck Press & Blow (NNPB). Both involve cutting a stream of molten glass into gobs that fall by gravity into blank moulds. In the B&B process, the gob is blown into shape, while in NNPB, pressing shapes the parison.

If you want a more detailed blog about these processes, leave a comment or reach out through the links below.

Stage 5: Annealing

A formed glass vessel is heat-treated and uniformly cooled in an annealing lehr, which helps prevent uneven cooling that can weaken the glass. This stage ensures the glass' strength and durability.

• Cold End Stage in Glass Bottle Production

Stage 6: Coatings

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There are usually two surface coatings applied to glass bottles and jars. One occurs before annealing at the hot end, and the second right after annealing at the cold end.

A thin layer of tin oxide is applied to the hot end using an organic or inorganic compound. Alternatives like titanium tetrachloride or organo titanate can also be used, but all serve the purpose of making the glass surface more adhesive to the cold end coating. On the cold end, an aqueous emulsion of polyethylene wax is applied.

These coatings prevent the containers from sticking together on conveyance, providing a virtually scratch-resistant surface. This reduces surface damage during use.

Stage 7: Quality Inspection

Glass containers undergo a comprehensive inspection, both automatically and manually.

Many defects can occur, from small cracks (checks) to foreign particles (stones) in the glass. Other issues include air bubbles, thin walls, and tears due to misalignment during the press and blow method.

Inspection equipment rejects defective containers and transmits information to the forming machine operator. Defective containers are marked with a mould number and returned to the furnace for remelting.

Stage 8: Secondary Processing

Manufacturers also offer additional services such as labeling using Applied Ceramic Marking (ACL) and screen-printed decorations. The iconic Coca-Cola bottle is a prime example of such decoration.

Stage 9: Packaging

Glass containers are usually packaged in bulk pallets, boxes, or bags. Automated machines such as palletizers help streamline this process. After packaging, the items are tagged, stored, and eventually shipped. In India, shrink and carton boxes are particularly popular for glass jar and bottle packaging.

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1.Choosing the raw material

The glass bottles are generally made of 7 to 12 different kinds of materials, and the primary materials used in the glass bottle manufacturing process are silica sand, sodium carbonate, limestone, dolomite, feldspar, borax, barium, and so on.

The most important raw material is silica as it determines the strength of the glass. The amount of silica can be chosen based on the type of glass to be made. The silica content is important as the melting point of the glass is inversely proportional to it.

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