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C.S.Purushothaman
CSP TRG AIDS - AUG 2008
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SCOPE
BASICS MANUFACTURE DESIGN FEATURES TYPES & PROPERTIES PERFORMANCE & TESTING
BASICS
What is Glass?
SUPERCOOLED LIQUID
LIQUID WHICH IS COOLED TO A STAGE WHERE ITS VISCOSITY IS SO GREAT THAT THE MOLECULES DO NOT MOVE FREELY ENOUGH TO FORM CRYSTALS
SILICA SAND
SILICA SAND
Three of most common rock forming minerals on earth. Chemically named: quartz sand / rock crystal Properties: Extremely heat durable
Chemical stack resistance
Chemically weathering:
Less stable minerals
SODA ASH
SODA ASH
Anhydrous sodium carbonate Texture: soft Color: grayish & white Appearance: lump / powder in nature
LIME
LIME
Includes hydrated lime Ca (OH)2 & quicklime CaO Only quicklime can use to make glass
MANUFACTURE
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Lighter weight
More than 40% lighter than 20 years ago.
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METALS USED TO IMPART COLOR TO GLASS Cadmium Sulfide Gold Chloride Cobalt Oxide Manganese Dioxide Nickel Oxide Sulfur Chromic Oxide Uranium Oxide Iron Oxide Selenium Oxide Carbon Oxides Yellow Red Blue-Violet Purple Violet Yellow-Amber Emerald Green Fluorescent Yellow, Green Greens and Browns Reds Amber Brown
Antimony Oxides
Copper Compounds Tin Compounds Lead Compounds Manganese Dioxide Sodium Nitrate
White
Blue, Green, Red White Yellow A "decoloring" agent A "decoloring" agent
Three standard furnace colours are Flint, Amber and Emerald Blue coloured bottle make product look white OPAL: MINUTE CRYSTALS OF FLUORINE COMPOUNDS ARE ADDED (CALCIUM FLUORIDE)
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CULLET
SORTING
SAND
OTHER RM
WEIGHED
MIXER
FOREHEARTH
MOULDING
COOLING
ANNEALING LEHR
PROTECTIVE COATINGS
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
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GOB FORMATION
Gobs ---to form blank mold Gob is one individual mass of molten glass which makes 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 bottlemaking 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.
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Orifice 12 mm to 50mm
GLASS MOULDING
BLOWING (Bottle or Jar) TWO STAGE MOULDING BLANK MOULD blank mold forms neck and initial shape parison mould where gob falls and neck is formed has number of sections finish section cavity section (made in two halves to allow parison removal) a guide or funnel for inserting gob a seal for gob opening once gob is settled in mold blowing tubes through the gob and neck openings BLOW MOULD - blow mold produce the final shape
GLASS MOULDING
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Gob delivery and settle-blow steps are similar to blow-and-blow forming. Parison is pressed into shape with a metal plunger rather than blown into shape The final blowing step is identical to the blow-and-blow process. Used for smaller necked containers. Better control of glass distribution
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Bottle Manufacture
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. The 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.
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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. The 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.
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ANNEALING
ANNEALING to reduce internal stresses; in annealing oven - Walls are comparatively thick and cooling will not be even. - The inner and outer skins of a glass become rigid - The still-contracting inner portion build up internal stresses - Uneven cooling develop substantial stresses in the glass. - Bottle passes through an lehr after removal from the blow mold. - LEHR is a belt passing through the controlled temperature oven at a rate of about 200mm to 300mm per minute. 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.
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SURFACE COATINGS
SURFACE COATINGS Purpose--- to reduce the coefficient of friction Reasons---The inner and outer surfaces have different characteristics The 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 scratchinhg and brusing can occur when surface rub. Surface scratching has lower breakage resistance Methods--- hot-end coating ; cold-end coatings The hot-end coating applied at the entrance to the annealing lehr to strength the glass surface Cold-end coatings depending on the filling process and end use. Typical cold-end coatings---oleic acid, monostearates, waxes, silicones, polyethylenes The label adhesive as one cold-end coating.
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DECORATION
Frosting Etching by Hydrofluric Acid (HF) / sand blasting expensive Printing
DESIGN FEATURES
BOTTLE PARTS
Finish is that part which receives the closure
Smooth round shapes---easily formed Suitable on filling lines Labeled at relatively high speeds Accurately positioned in spot-labeler Greater strength-to-weight ratios Better material utilization
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BOTTLE DEFECTS
Flat shapes inherent problems. bird swing and spike defects. Spikes --- glass projections inside the bottle Bird swing--- glass thread joining the two walls Careful design to avoid stress points.
angular shapes---difficult to form
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SIDES
Sides The most generalized areas of the bottle. Labeling styles and preventing scuffing must be considered. Bottles designed with label panels to prevent scuffing. The panel may have prominent base and shoulder ridges. In angular bottles, rounded corners are preferable for wraparound or three-side labeling. Spot labeling is normally a one- or two-sided application. Labeling of non-round shapes is slower than for round shapes.
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BONATED BEVERAGES
Carbonated Beverages The pressure factors: gas dissolved in the product. Beverage producers express this as the number of volumes of gas dissolved in a unit volume of the product. For example, if a 48 oz. volume of carbon dioxide at standard conditions is dissolved in 12 oz. of beverage, then the beverage is said to yield 4 gas volumes. Carbonated beverage and beer bottles internal gas pressure : soft drink 0.34 millipascal (50 psi), beer 0.83 millipascal (120 psi). capped well The loss of bottle strength Bottle designs ---round in cross section gently curving radii to maximize strength.
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Regal
Ensures freshness and taste Nontoxic FDA-approved 2.5 g/cc
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cooled quickly
principle component ---silica (quartz), Ingredients of components makes different formulations. Mineral compounds used to achieve improved properties: decolorizeration, Clarity, Colouring Other glass types used for special packaging purposes. lead compounds, boron compounds, borosilicate glasses
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TYPES OF GLASS
Although INERT Sodium and other ions can leach out on ceratin solution. USP Type-I Borosilicate Flint (clear), Amber (brown) glass vials, USP Type-II De Alkalized Soda Lime Glass(type3) that has been treated in the lehr with sulphur to reduce alkali solubility. The treatment produces a disccoloured appearance. USP Type-III conventional soda glass
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Has higher levels of sodium hydroxide and calcium oxide. It is less resistant to leaching than Type I but more resistant than Type III. GOOD ALKALI RESISTANCE It can be used for products that remain below pH 7 for their shelf life
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USP TYPE III SODA LIME GLASS Acceptable in packaging some dry powders which are subsequently dissolved to make solutions or buffers. It is also suitable for packaging liquid formulations that prove to be insensitive to alkali. Type III glass should not be used for products that are to be autoclaved, but can be used in dry heat sterilization
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Is a general purpose glass and is used for nonparenteral applications where chemical durability and heat shock are not factors. These containers are frequently used for capsules, tablets and topical products.
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VERTICAL LOAD Forces of this nature might be produced during capping or through stacking products on top of each other. To help ensure glass containers have adequate vertical load strength, we test to BS EN ISO 8113-2004 using a Universal Testing Machine.
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IMPACT TESTING To help ensure glass containers have an adequate impact resistance, we can test to standard manufacturing codes of practice using an industry standard Pendulum Impact Tester.
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THERMAL SHOCK Hot-fill or heat-treated glassware can be tested for thermal shock resistance to ensure the product is fit for the intended purpose. Testing can be carried out to ASTM C149 and BS EN ISO 7459 either as pass/fail test typically at 42OC downshock or progressive testing to complete sample failure.
EFFECT OF SUDDEN TEMPERATURE CHANGE EFFECT IS MINIMAL IF BOTH SIDES ARE HEATED OR COOLED SIMULTANEOUSLY EFFECTI IS PROMINENT WHEN ONE SURFACE IS HOT AND THE OTHER SURFACE IS CHILLED
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COATING PERFORMANCE Assessment of surface protection can be carried out by use of slip tables and hot end coating technology. The longevity of the coating performance can be assessed using line simulator, whereby bottle to bottle abrasion damage which may be expected to occur on a filling line can be replicated and the subsequent damage of the container tested. This is of particular use for returnable glassware.
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INTERNAL PRESSURE RESISTANCE Carbonated beverage bottles need to be able to withstand without failure the pressure produced by their contents over long periods.
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ON-LINE INSPECTION OF GLASS BOTTLES 1.Bottle Spacer. This machine is pre-set to create a space between the bottles on the conveyer to avoid bottle to bottle contract. 2.Squeeze Tester. Each bottle is passed between discs that exert a force to the body of the container. Any obvious weakness or crack in the bottle will cause it to fail completely with the resulting cullet being collected by a return conveyor running underneath. 3.Bore Gauger. The internal and external diameter at the neck finish entrance to the bottle and the bottle height are measured. Bottles outside specification are automatically rejected by means of a pusher positioned downstream from the gauger.
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4.Check Detector. Focuses a beam of light onto areas of the container where defects are known to occur from previous visual examinations, any crack will reflect the light to a detector, which will trigger a mechanism to reject the bottle. 5.Wall Thickness Detector. This test uses dielectric properties of the glass, the wall thickness can be determined by means of a sensitive head which traverses the body section of the container. A trace of the wall thickness is then obtained and bottles falling below a specified minimum will be automatically rejected. 6.Hydraulic Pressure Tester. A test carried out on bottles which will be filled with carbonated beverages and gauges the internal pressure of every bottle before it is packed.
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7.Visual Check. Bottles are passed in front of a viewing screen as a final inspection.
Glass failure is usually as a result of thermal shock or impact stresses. Each glass container has a maximum thermal expansion threshold and a maximum vertical load stress, which it can withstand without cracking. These values should be known before it is used for a particular application. The shape of the container will influence its strength, smooth edges result in the formation of a stronger container than one with rectangular or sharp edges
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Defects are classified as Critical, those that are hazardous to the user and those that make the container completely unusable.
Major, those that materially reduce the usability of the container or its contents Minor, those that do not affect the usability of the container, but detract from its appearance or acceptability to the customer.
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Critical Defects in Glass Bottles or Containers 1.Stuck Plug. A piece of glass, usually very sharp, projecting inwards just inside the neck bore 2.Overpress. Is a defect where a small ridge of glass has been formed on the sealing surface of the finish 3.Split. An open crack starting at the top of the finish and extending downward. 4.Check. A small, shallow surface crack, usually at the bore of the container 5.Freaks. Odd shapes and conditions that render the container completely unusable. Bent or cocked necks are a common defect of this type. 6.Poor Distribution. Thin shoulder, slug neck, choke neck, heavy bottom are terms used to describe the uneven distribution of glass. 7.Soft Blister. A thin blister, usually found on or near the sealing surface. It can however show up anywhere on the glass container.
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8.Choked Bore. Here excess of glass has been distributed to the inside of the finish or opening 9.Cracks. Partial fractures, usually found in the heel area. 10.Pinhole. Any opening causing leakage. It occurs most often in bottles with pointed corners. 11.Filament. A hair-like string inside the bottle. 12.Spike. Spikes are glass projections inside the bottle. 13.Bird Swing. Is a glass thread joining the two walls of the container
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Some Major Defects Commonly Found in Glass Containers 1.Chipped Finish. Pieces broken out of the top edge in the manufacturing process. 2.Stone. Small inclusion of any non-glass material 3.Rocker Bottom. A sunken centre portion on in base of the container 4.Flanged Bottom. A rim of glass around the bottom at the parting line
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Some Minor Defects Commonly Found in Glass Containers 1.Suncker Shoulder. Not fully blown, or sagged after blowing 2.Tear. Similar to a check, but opened up. A tear will not break when tapped, a check will. 3.Washboard. A wavy condition of horizontal lines in the body of the bottle. 4.Hard Blister. A deeply embedded blister that is not easily broken. 5.Dirt. Scaly or granular nonglass material. 6.Heel Tap. A manufacturing defect where excess glass has been distributed into the heel 7.Mark. A brush mark is composed of fine vertical laps, e.g. oil marks from moulds. 8.Wavy bottle. A wavy surface on the inside of the bottle. 9.Seeds. Small bubbles in the glass 10.Neck ring seam. A bulge at the parting line between the neck and the body.
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TOLERANCE
TOLERANCE
Tolerances as per GLASS PACKAGING INSTITUTE CAPACITY 1% for large bottles and upto 15% for small bottles WEIGHT HEIGHT generally 5% 0.5 to 0.8% overall HEIGHT
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TOLERANCE
The following are examples of some permitted tolerances: Vertical load control values
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CAPACITY
Nominal Capacity (ml) up to and including 100 125 150 175 200 250 300 350 400 Tolerances (ml) 2.7 3.0 3.3 3.5 3.8 4.2 4.6 5.0 5.3 Nominal capacity (ml) up to and including 450 500 600 700 800 900 1000 1250 1500 Tolerances (ml) 5.7 6.0 6.5 7.1 7.6 8.0 8.4 12.5 15.0
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25.0 36.5 50.0 62.5 75.0 87.5 100.0 112.5 125.0 137.5 150.0
0.8 0.9 1.1 1.2 1.4 1.5 1.7 1.8 2.0 2.1 2.3
0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
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Height H (mm) up to and including 120 150 175 200 225 250
Tv (mm)
2.2 2.7 3.1 3.4 3.9 4.2
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THINK
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