UNIT – III - GLASS AND METALS

• Glass – Chemistry, properties, coatings, defects and

application areas;
• Metals – Tin, Steel, Aluminum –Cans, drums, sheet –
Materials, properties, treatment,
• Coatings - manufacturing process, recycling process;
• Foil – Materials, characteristics, decoration,
lamination and metallization methods.

• http://www.glasswebsite.com/video/fgmd.asp
History:
• The history of creating glass can be traced back to 3500 BC
in Mesopotamia.
• The term glass developed in the late Roman Empire.
• It was in the Roman glassmaking center at Trier, now in modern Germany,
that the late-Latin term glesum originated, probably from Germanic word
for a transparent, lustrous substance (Bright, shining)
• Glass is an amorphous (nonCrystalline) solid material.
• Glasses are typically brittle and optically transparent.
• The most familiar type of glass, used for centuries
in windows and drinking vessels, is soda-lime glass, made of about
75% silica (SiO2) + Na2O, CaO, and several minor additives.

• For many applications (bottles, eyewear) polymer glasses (acrylic

glass, polycarbonate, polyethylene terephthalate) are a lighter
alternative to traditional silica glasses.
Reusable soda-lime glass milk bottles
Old window made from soda-lime flat glass, Jena, Germany.
• Glass, as a substance, plays an essential role in science and
industry.
• Its chemical, physical, and in particular optical properties make it
suitable for applications such as:
 flat glass,
 container glass, optics and optoelectronics material,
 laboratory equipment,
 thermal insulator (glass wool),
 reinforcement materials (glass-reinforced plastic, glass
fiber reinforced concrete),
 glass art (art glass, studio glass).
Glass making ingredients:

• Silica sand (silicone oxide) – 68 – 73%

• Limestone (Calcium Carbonate) – 10 – 13%
• Soda ash (Sodium carbonate) – 12 – 15%
• Alumina (Aluminum oxide) – 1.5 – 2%
Advantages – Glass packaging material:

• Inert to most chemicals.

• Foods do not attack glass.
• Clarity allows product visibility.
• Rigidity of glass means that container shapes and volumes do
not change under vacuum (or) under pressure.
• Stable at high temperature – makes it suitable for hot fill and
retortable products.
Disadvantages of Using Glass Containers as Food
Packaging Materials:

• Weaknesses in glass containers are the single biggest factor

limiting the use of glass as a food packaging material.
• Expensive food packaging material
Main properties of glass:
These are the main characteristics of glass:
• Solid and hard material
• Disordered and amorphous structure
• Fragile and easily breakable into sharp pieces
• Transparent to visible light
• Inert and biologically inactive material.
• Glass is 100% recyclable and one of the safest packaging materials
due to its composition and properties
• Glass is used for architecture application, illumination,
electrical transmission, instruments for scientific research,
optical instruments, domestic tools and even textiles.
• Glass does not deteriorate, corrode, stain or fade and
therefore is one of the safest packaging materials.
• These properties can be modified and changed by adding other
compounds or heat treatment.
Glass types:
• Float Glass
• Borophosphosilicate Glass
• Bulletproof Glass
• Crown Glass
• Fluorosilicate Glass
• Frosted Glass
• Insulated Glass
• Laminated Glass
• Heat Resistant Glass
• Toughened Glass
Advantages of Using Glass Containers as Food
Packaging Materials:
• Inert
• Impermeable
• No odour
• Versatility in shape and colour
• Reusable
• Suitable for use in the microwave
• Excellent clarity
• Glass containers are distinctive, convenient and
practical
• Glass containers are used for premium quality foods
Disadvantages of Using Glass Containers as Food
Packaging Materials:

• Weaknesses in glass containers are the single biggest

factor limiting the use of glass as a food packaging
material.
• Expensive food packaging material
6 broad classifications of glass defects:

• Checks (A small crack in the glass, also known as

a check, in the glass container industry)
• Seams (A line or depression left by a cut)
• Non-glass inclusions (Something included)
• Dirt, dope, adhering particles or oil parks
• Freaks and malformations,
• Marks
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.
Critical Defects in Glass Bottles or Containers:
• Stuck Plug - A piece of glass, usually very sharp,
projecting inwards just inside the neck bore
• Overpress - Is a defect where a small ridge of glass
has been formed on the sealing surface of the finish
• Split -An open crack starting at the top of the finish
and extending downward.
• Check - A small, shallow surface crack, usually at the
bore of the container
• Freaks - Odd shapes and conditions that render the
container completely unusable. Bent or cocked necks
are a common defect of this type.
Stuck Plug
Split
• Poor Distribution - Thin shoulder, slug neck, choke
neck, heavy bottom are terms used to describe the
uneven distribution of glass.
• Soft Blister - A thin blister, usually found on or near
the sealing surface. It can however show up anywhere
on the glass container.
• Choked Bore - Here excess of glass has been
distributed to the inside of the finish or opening
• Cracks - Partial fractures, usually found in the heel
area.
• Pinhole - Any opening causing leakage. It occurs
most often in bottles with pointed corners.
• Filament - A hair-like string inside the bottle.
• Spike - Spikes are glass projections inside the bottle.
• Bird Swing - Is a glass thread joining the two walls
of the container
Some Major Defects Commonly Found in Glass
Containers:
• Chipped Finish - Pieces broken out of the top edge in
the manufacturing process.
• Stone - Small inclusion of any non-glass material
• Rocker Bottom - A sunken centre portion on in base
of the container
• Flanged Bottom - A rim of glass around the bottom
at the parting line
Some Minor Defects Commonly Found in Glass
Containers:
• Suncker Shoulder - Not fully blown, or sagged after
blowing
• Tear - Similar to a check, but opened up. A tear will
not break when tapped, a check will.
• Washboard - A wavy condition of horizontal lines in
the body of the bottle.
• Hard Blister - A deeply embedded blister that is not
easily broken.
• Dirt - Scaly or granular non glass material.
• Heel Tap - A manufacturing defect where excess glass
has been distributed into the heel
• Mark - A brush mark is composed of fine vertical
laps, e.g. oil marks from moulds.
• Wavy bottle - A wavy surface on the inside of the
bottle.
• Seeds - Small bubbles in the glass
• Neck ring seam - A bulge at the parting line between
the neck and the body.

• Defects:
Glass making:
Raw Materials:
• There are four main ingredients used to manufacture
glass:
• Silica sand, soda ash, limestone and recycled glass
(cullet).
• There are also a variety of minor ingredients, (some
are included to give glass its colour).
• These raw materials are simple and readily available.
Molten Glass
Glass manufacturing:

Furnace:
• The two furnaces are capable of producing 210 and
250 tonnes of glass per day.
• Firing is by natural gas through the side ports and
the glass temperature in the furnace ranges from
about 1100 – 1590° C.
Forming:
• From the furnace, the melted glass goes to the refiner
and then the forehearth where the glass is
“conditioned” before entering a bottle forming
machine. These are either double or triple gob
machines.

Annealing:
• Anneal is to toughen (glass or metals) by heating and
slow cooling.
• Quality Inspection:
• Distribution / Customer
• Recycling
http://heraeus-
targets.com/en/technology/_sputteringbasics/sputte
ring.aspx
http://heraeus-
targets.com/en/products_1/_glass/Glass.aspx

http://www.farwestfibers.com/Products-and-
Services/Glass.html
Glass coating:
• To prevent the inherent strength of glass bottles – it is
necessary to prevent abrasion and scratching
resistance on the glass bottles.
• Coated bottles are several times stronger than
uncoated.
• Inner and outer surface exhibit different
characteristics.
• Inner surface has to sterile and chemically inert.
• Outer surface takes the plane of molded surface.
• Causes rough surface with high coefficient of friction
creating problems in high speed filling operations.
• For that the internal layer provided with high scuff
resistant layer and external treatment to improve
scratch resistance.
• Silicon coat generally used in both sides.
• Should be non toxic.
• Silicon applied by spray system to improve strength of
bottle.
• Exterior surface also coated to avoid friction.
Coating techniques
Glass Manufacturing

http://www.jbermanglass.com/glass/glass_texture_coati
ngs.html

http://www.quantumcoating.com/new.asp#june10

http://www.glasswebsite.com/video/mirror.asp

http://www.glasswebsite.com/video/default.asp
In Pharmaceutical packaging
In Pharmaceutical packaging
Mirrors used in busses
Metals – Tin, Steel, Aluminium:
Metal:

• A metal is a chemical element that is a

good conductor of both electricity and heat and
forms cations and ionic bonds with non-metals.
Categories:
• Base
• Ferrous
• Noble
• Precious
Base metal:
• Zinc, a base metal, reacting with an acid.
• In chemistry, the term base metal is used informally
to refer to a metal that oxidizes or corrodes relatively
easily, and reacts variably with dilute hydrochloric
acid (HCl) to form hydrogen.
• Examples include iron, nickel, lead and zinc.
• Copper is considered a base metal as it oxidizes
relatively easily, although it does not react with HCl.
• It is commonly used in opposition to noble metal.
Ferrous metal:
• The term "ferrous" is derived from the Latin
word meaning "containing iron". This can include
pure iron, such as wrought iron, or an alloy such
as steel. Ferrous metals are often magnetic, but not
exclusively.
Noble metal:
• Noble metals are metals that are resistant
to corrosion or oxidation, unlike most base metals.
• They tend to be precious metals, often due to
perceived rarity.
• Examples include tantalum, gold, platinum, silver
and rhodium.
Precious metal:

• A precious metal is a rare metallic chemical

element of high economic value.
• The best-known precious metals are gold and silver.
• Other precious metals include the platinum
group metals: ruthenium, rhodium,
palladium, osmium, iridium, and platinum of which
platinum is the most widely traded.
Role of Metals in Packaging Industry:
http://www.hardwaremarketplace.com/articles/2009/04
/role-of-metals-in-packaging-industry.html

• Metals have been the base of packaging industry

since a long time.
• The arrival of other cost effective &
competitive packaging materials have cut its share.
• But the functional contribution of metals can not be
undetermined.
TIN PLATE AND ALUMINIUM:
• Tin plate is often used for cans, screw tops and
aerosols.
• Tin plate cans are normally used for packaging
foods such as processed vegetables and products
such as tuna and many more.
• The most recognisable ‘metal’ material used for
packaging food products is aluminium.
• It is used for drink cans, trays, wrappings, inner
bags and in laminates.
• It is strong and withstands heat and processing.
• It can also withstand the internal pressure of gases
that have been added to the product inside the can.
• Aluminium cans are also lightweight.
 http://www.sciencebase.com/science-blog/heavy-
metal-packaging.html
 http://www.hindustantin.biz/index.php
 http://www.tatatinplate.com/stages.shtm
 http://www.mmw.co.in/food-tin-cans.html
POLYMER-COATED STEEL:

• Protact® is a chromium or tin based steel with a

polymer coating that combines the best
characteristics of steel and plastic for packaging
purposes.
• This safe, versatile and attractive packaging
material is already used in a range of cans, domes,
cones, easy-open ends and rings for peelable ends.
• It is also suitable for non-packaging applications.
http://www.tatasteelpackaging.com/assets/files/CPT%
20Protact%20polymer-
coated%20steel%20(web%20quality)(1).pdf
FEATURES:

• Non Reactive
• Effective for Perishable Items
• Available in different Shapes and Sizes
• Easily open able Lid
• Can be customized
Tin can:
• A tin can, tin steel can, or a can, is a
sealed container for the distribution or storage of
goods, composed of thin metal.
• Many cans require opening by cutting the "end"
open; others have removable covers.
• Cans hold diverse contents: foods, beverages, oil,
chemicals, etc.
• "Tin" cans are made of tinplate (tin-coated steel).
In some locations, cans made of aluminum are
called "tin cans".
• In countries and regions that use the metric system
of measures, most tins are made in 250, 500,
750 ml (millilitre) and 1 L (litre) sizes.
PROPERTIES:
· Tin is a white metal at room temperature.
· Tin is soft.
· Tin is highly corrosion-resistant and fatigue-
resistant.
· Tin is non-toxic.
· Tin is highly malleable (able to be shaped).
· Tin alloys easily with other metals.
· Tin has a low melting point (232°C).
· Tin is easy to recycle.
http://aluminium.org.au/packaging

http://www.eaa.net/upl/4/default/doc/Aluminium%20i
n%20packaging%20brochure.pdf
Aluminium in Packaging:

• Provides impermeable barrier to protect food,

beverage, Pharmaceuticals.
• Minimises wastage.
• Good formability and machiniability.
• Highly corrosion resistant.
• Chemically neutral.
• High strength to weight ratio.
• Transportation cost reduces – bcoz of less weight.
Tin / Aluminium Cans Recycling:

http://www.lotfi.net/recycle/acan.html

http://www.farwestfibers.com/Products-and-
Services/Metal.html
ALUMINIUM FOIL:
• Aluminium foil is aluminium prepared in thin metal
leaves, with a thickness less than 0.2 millimetres
(8 mils), thinner gauges down to 6 µm (0.2 mils) are
also commonly used.

• The foil is pliable, and can be readily bent or

wrapped around objects.
• Thin foils are fragile and are sometimes laminated
to other materials such as plastics or paper to make
them more useful.
• Approximately 75% of aluminium foil is used
for packaging of foods, cosmetics, and chemical
products, and 25% used for industrial applications
(e.g. thermal insulation, cables and electronics).

• In North America, aluminium foil is known

as aluminum foil.
• It is also sometimes called Reynolds
wrap after Reynolds Metals, the leading
manufacturer in North America.
PROPERTIES:
• Aluminium foils thicker than 25 µm (1.0 mil) are
impermeable to oxygen and water. Foils thinner
than this become slightly permeable due to minute
pinholes caused by the production process.
• Aluminium foil has a shiny side and a matte side.
• The shiny side is produced when the aluminium is
rolled during the final pass.
Aluminium Foil
Aluminium Foil
PACKAGING END USES:
• Semi Rigid Foil Containers - Bakery Goods, Frozen
Foods and other
• Caps, cap-liners and packaging closures for
Beverages, milk, foods and other
• Composite cans and canisters - Powdered drinks,
auto supplies, Food snacks, Citrus and other juices,
Refrigerated dough, other frozen food products
• Flexible Packaging end uses - labels, cartons, over
wraps, wrappers, capsules, bags, pouches, seal
hoods and overlays for semi rigid foil containes.
• Military specification packaging
ALUMINUM FOIL APPLICATIONS:

• Containers and Packaging

• Semi-Rigid Foil Containers
• Household & Institutional Foil
• Food Service Product
• Other Foil Uses
• Foil Building Products
• Aluminum Foil Capacitors
• Aluminum Foil Finstock
• Aluminum Foil Strip Conductor
• Aluminum Honeycomb
• Aluminum Foil Printing Plates
• Nameplates & Product Labels
• Caul Stock
• Foil Printing Stocks
• Other Foil Applications
• Metalizing is the general name for the technique of
coating metal on the surface of non-metallic objects.

• The process of coating a glass surface with metallic

silver, making the glass mirror one of the earliest
items being metallized.
 Metallized Film
golden glossy metallization
Metallized Coffee Packaging
Metallized packaging Films: