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IN
PACKAGING
C.S.Purushothaman
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
Naturally:
Mechanical & chemical weathering of quartz-bearing
igneous & metamorphic rocks
Chemically weathering:
Less stable minerals
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
MANUFACTURE
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Lighter weight
More than 40% lighter than 20
years ago.
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Yellow
Gold Chloride
Red
Cobalt Oxide
Blue-Violet
Manganese Dioxide
Purple
Nickel Oxide
Violet
Sulfur
Yellow-Amber
Chromic Oxide
Emerald Green
Uranium Oxide
Iron Oxide
Selenium Oxide
Reds
Carbon Oxides
Amber Brown
Antimony Oxides
White
Copper Compounds
Tin Compounds
White
Lead Compounds
Yellow
Manganese Dioxide
A "decoloring" agent
Sodium Nitrate
A "decoloring" agent
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CULLET
SAND
SORTING
WASHING & SIEVING
CRUSHED TO
15 20 mm dia
WEIGHED
MIXER
FURNACE
1500 deg C
FOREHEARTH
COOLING
ANNEALING LEHR
PROTECTIVE COATINGS
OTHER RM
GLASS MELTING
Cullet + SAND + OTHER RM MELTED in furnace (15000C)
(100 to
500 MT)
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GOB FORMATION
Gobs ---to form blank mold
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
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GLASS MOULDING
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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
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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
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
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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
to avoidtostress
angulardesign
shapes---difficult
form
points.
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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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TYPES &
PROPERTIES
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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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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.
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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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RESIDUAL STRAIN
Measurement of annealing
stresses/residual strain to ASTM C148;
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TOLERANCE
TOLERANCE
Tolerances as per GLASS PACKAGING INSTITUTE
CAPACITY 1% for large bottles and
upto 15% for small bottles
WEIGHT
generally 5%
HEIGHT
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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/Diameter
Tolerances
D (mm) up to and
including
TD (mm)
H (mm) up to and
including
TH (mm)
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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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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Up to 60
1.1
1.5
0.8
>61 to 71
1.4
1.8
0.9
>71 to 81
1.5
1.9
1.0
>81 to 96
1.7
2.0
1.1
>96 to 110
1.8
2.2
1.3
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THINK
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