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GLASS IN PACKAGING

C.S.Purushothaman
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SCOPE
BASICS MANUFACTURE DESIGN FEATURES TYPES & PROPERTIES PERFORMANCE & TESTING

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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

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What is glass made of?

Sand 70% Soda Ash 15% Limestone 10%

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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

FORMATION OF SILICA SAND


Naturally:
Mechanical & chemical weathering of quartz-bearing igneous & metamorphic rocks

Chemically weathering:
Less stable minerals

break down to become silica sand

SODA ASH

SODA ASH
Anhydrous sodium carbonate Texture: soft Color: grayish & white Appearance: lump / powder in nature

FORMATION OF SODA ASH


Naturally:
Erosion of igneous rock form sodium deposits Transport by waters as runoffs & collect in basins When sodium comes in contact with CO2, precipitates out sodium carbonate

THE SOLVAY PROCESS FOR THE MANUFACTURE OF SODA ASH (NAHCO3).

LIME

LIME
Includes hydrated lime Ca (OH)2 & quicklime CaO Only quicklime can use to make glass

MANUFACTURE

Cullet Recycled glass


(from plant and post consumer) used at levels as high as 80% when available. It is needed and added to enhance the melting rate and it significantly reduces energy required for glass production.

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Glass Container Recycling


100% recyclable
Can be recycled again and again with no loss in quality or purity In 2005, 25.3% of glass container recycled

Good for the environment


recycling glass reduces consumption of raw materials, extends the life of plant equipment, and saves energy

Lighter weight
More than 40% lighter than 20 years ago.

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Benefits of Using Quality 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.


Glass has an unlimited life, it can be recycled

over and over again.


Lesser sodium oxide stronger the glass Aluminium oxide increases the hardness & durability. Use of Na2SO4 & Arsenic reduces blisters

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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

WASHING & SIEVING CRUSHED TO 15 20 mm dia

WEIGHED

MIXER

FURNACE 1500 deg C

FOREHEARTH

GOBS CUT OFF

MOULDING

COOLING

ANNEALING LEHR

PROTECTIVE COATINGS

BOTTLES & JARS

SCHEMATIC DIAGRAM OF GLASS MANUFACTURING

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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Furnace draw-off orifice and gob shears

Orifice 12 mm to 50mm

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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

TWO TYPES OF PROCESSES


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GLASS MOULDING

TWO TYPES OF PROCESSES


BLOW & BLOW
PRESS & BLOW

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BLOW & BLOW


Blow-and-blow process--- for narrow-necked bottles The two processes differ according to the parison producing. Blow-and-blow process: 1. Gob dropped into the blank mold through a funnel-shaped guide (985C) 2. parison bottomer replaced guide ;air blown into settle mold to force the finish section. At this point the bottle finish is complete. 3. Solid bottom plate replaced parison bottomer ; air is forced to expand the glass upward and form the parison. 4. Parison removed from the blank mold, rotated to a right-side-up orientation for placement into the blow mold. 5. 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.

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BLOW & BLOW

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PRESS & BLOW


press-and-blow process--- for wide-mouthed jars

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

Press and blow forms the parison by mechanical action

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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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INSPECTION & PACKAGING


INSPECTION AND PACKING Use mechanical and electronic means. 1) Squeeze testers subject the container walls to a compressive force ( between two rollers) 2) Plug gauges check height, perpendicularity, inside and outside finish diameters. 3) Optical devices inspect for stones, blisters, checks, bird swings, and other blemishes and irregularities by rotating the container past a bank of photocells (Figure 6.4). Faulty containers crushing into cullet. Transported in reusable corrugated shippers; Shipped on pallets Automatic equipment used to clear tiers off the pallet and feed into the filling machine.

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DECORATION
Frosting Etching by Hydrofluric Acid (HF) / 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.

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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FINISH & CLOSURES


FINISH AND CLOSURES Finishes are broadly classified according to diameter ,sealing method, and special features. Continuous-thread (CT), lug, crown, threaded-crown, and rollon are common finish designs. Closures are based on the cost, utility, and decoration thread profile has a curved or partially semicircular profile COLOURING Flint Clear & Transpareent Green Chrome oxide for emerald green upto 5% Brown Iron and sulphur for amber Blue Cobalt oxide for Blue Opal Opaque white

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NECK & SHOULDER AREAS


Neck and Shoulder Areas The impact on filling, air displacement, and dispensing. Fill level in long narrow necks Headspace for thermal expansion and facilitate filling. Manufacturing defect ---choke neck Ridge on the sealing surface---overpress Upper shoulder --- below the neck. Shoulder and neck blending ---important design and production. lower shoulder--- the integration point between the upper shoulder and the body. Contact area

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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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HEEL & BASE


Heel and Base High-abuse area--- start high from the base curving into the base to a suitable base diameter. Body-to-base curve should combine 3 radii. The largest blends body to heel, the smallest blends heel to base. Diameter as large as possible as a good design. Center of the base ensure a flat, stable bottom . Stippled or knurled on the circular bearing surface to protect the scratches not to weaken the body during handling and usage. Ketchup bottles and other sauce bottles require: heel and base be heavier and contoured when expelling the contents. Wide-mouthed jar bases have designed-in stacking features. Container base fits into recessed cap. Indented container base fits over cap. Heel tap --- excess glass distributed to the heel.

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STABILITY & MACHINABILITY


Stability and Machinability bottle's stability the center of gravity ; the base surface area problem in manufacturing ---tall and narrow bottles handling and labeling in packaging line --- high center Short round oval bodies --- efficient for machine handling and labeling problems. baby food ; cold cream jars. As much as possible, bottles should be designed to be all-around trouble free to manufacture, fill, close, and ship. Some designs are inherently weaker or more prone to cause trouble in their filling and the distribution cycle than others.

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VIALS & AMPOULES


Vials and ampoules Vials and ampoules--- mainly for pharmaceuticals and sera Preformed tubing stock Sealed glass containers Constriction--- easy fracture stress concentration coated with a ceramic paint Standard sizes ---1, 2, 5, 10, and 20 ml. Serum vials a rubber septum ; an aluminum neck ring. a needle cannula to withdraw serum can be accessed several times. standard sizes--- 1, 2, 3, 5, 10, and 20 ml. Tumblers --- wide-mouthed containers Carboys ---bulk containment for acids or chemicals.

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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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TYPES & PROPERTIES

Benefits of Glass Packaging


Inert

Regal
Ensures freshness and taste Nontoxic FDA-approved 2.5 g/cc

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Glass Types and General Properties


inorganic substance fused at high temperatures and

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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Glass Types and General Properties


Advantages as a packaging material: inert perfect food container. impermeability clarity regal image rigidity stable at high temperatures Disadvantages : fragility high weight high energy costs

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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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USP TYPE I BOROSILICATE (neutral) GLASS


TYPE 1 ADDITION OF 6% BORON REDUCES LEACHING ACTION Least reactive glass available for containers. It can be used for all applications and is most commonly used to packaged water for injection, UN-buffered products, chemicals, sensitive lab samples, and samples requiring sterilization. All lab glass apparatus is generally Type I borosilicate glass. Type I glass is used to package products which are alkaline or will become alkaline prior to their expiration date

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USP TYPE II DE ALKALIZED SODA LIME GLASS

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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USP TYPE NP SODA LIME GLASS

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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PERFORMANCE & TESTING

PERFORMANCE & TESTING


It is important that containers comply with specification and general industry guidelines in order to withstand the normal stresses and mechanical abuse right through until the end user has finished using it.

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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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RESIDUAL STRAIN Measurement of annealing stresses/residual strain to ASTM C148;

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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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There are 6 broad classifications of glass defects


1.Checks 2.Seams 3.Non-glass inclusions 4.Dirt, dope, adhering particles or oil parks 5.Freaks and malformations, and 6.Marks

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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

DIAMETER 1.5% for 200mm & 3% for 25mm

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TOLERANCE
The following are examples of some permitted tolerances: Vertical load control values

Glass bottle Refillable Non-refillable

Vertical load 6000N 4000N

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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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BODY AND HEIGHT DIMENSIONS


Body/Diameter Tolerances D (mm) up to and including TD (mm) H (mm) up to and including TH (mm) Height Tolerances

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

25 50 75 100 125 150 175 200 225 250 275 300

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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VERTICALITY CONTROL VALUES FOR VERTICALITY

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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MINIMUM GLASS THICKNESS VALUES


Body overall Diameter (mm) Minimum glass thickness (mm) Non-refillable Refillable bottles Surface protected bottles non-refillable bottles

Up to 60 >61 to 71 >71 to 81 >81 to 96 >96 to 110

1.1 1.4 1.5 1.7 1.8

1.5 1.8 1.9 2.0 2.2

0.8 0.9 1.0 1.1 1.3

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THINK
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