mbaa rocky mountain district technical summit june 25, 2010 everything’s better in glass connie...
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MBAA Rocky Mountain DistrictTechnical Summit June 25, 2010
Everything’s Better in GlassConnie Maxwell, Quality ManagerO-I Windsor, Colorado
Owens-Illinois, Inc. Global Glass Industry Update 2
Owens-Illinois, Inc.
• Founded 1903 in Toledo, Ohio
• Operating in 22 countries
78 glass factories
169 furnaces
446 machines
• 23,000 employees
Hot End, Windsor Plant, CO
O-I North America #1
O-I Europe #1
O-I Asia Pacific #1
O-I South America #1
O-I Global Glass Profile
•19 manufacturing plants• 6,000 employees• 1.2 million tons of recycled glass
•10 manufacturing plants• 3,500 employees• 0.6 million tons of recycled glass
•11 manufacturing plants• 4,600 employees• 0.4 million tons of recycled glass
•38 manufacturing plts• 8,500 employees• 3.0 million tons of recycled glass
O-I North America Facilities
1 Auburn, NY2 Crenshaw, PA3 Brockway, PA4 Toano, VA5 Danville, VA6 Winston-Salem, NC7 Atlanta, GA8 Zanesville, OH9 Lapel, IN10 Streator, IL11 Muskogee, OK12 Waco, TX13 Portland, OR14 Oakland, CA15 Tracy, CA16 Los Angeles17 Windsor, CO18 Brampton, Ontario19 Montreal, Quebec
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Why Everything’s Better in Glass
• Infinitely recyclable with no loss of quality• No flavor or chemical transfer to contents
of container• Takes less energy to re-melt a glass
container than to melt the raw materials
The Glass Container FactoryHOT END
COLD END
Batch and Furnace
Forming
Surface Treatment
Selecting / Inspection Carton Assembly
Palletizing Shipping
Batch House
•Raw Material Unloading –Truck or Rail
•Storage –Individual Silos
•Batch weighing –± 0.1 % Accuracy
•Batch Mixing •Mixed Batch Transport
1) Raw Materials
70% Sand15% Soda Ash12% Limestone Plus 3% Colorants and Oxidizers
Batch composition:
2) CulletUp to 50% recycled glass from internal plant sourcesand recycling centers can be used. Cullet aids in fuel efficiency and melting in the furnace.
Exhaust Flue
Doghouse(Batch Delivery) Melter
Refiner
Throat End Wall
Ports (Fuel)
Ports (Fuel)
Exhaust Port
Alcove
Forehearth
Windsor PlantOxygen Fueled Furnace
Feeder
Forming Machine
Forming Machine
Melter Area
Glass Flow
Glass Flow
Batch Delivery
Entry into refiner / alcoveleading to forehearth
Furnace Interior
Glass FormationApproximate Temperatures (Degrees F.)
•Melting (Furnace) 2750 degrees•Conditioning (Forehearth) 2100 degrees.•Gob Formation / Forming 1700 degrees•After Formation (Softening Point) 1300 degrees•Lehr Entry (Annealing) 900 degrees
Batch and Furnace
After melting in the furnace, the glass flows into a forehearth where further conditioning takes place to prepare the glass
for the forming process.
Feeder
Forehearth
Feeder
Glass is formed into “Gobs” bya ceramic tube pushing the glass through orifices or openings at the base of the feeder.
The number of orifices is equal to the number of bottles produced on each section of the machine.
TUBE
A gob is a specific amount of molten glass that will be formed into a glass container.
FeederWhat is a gob?
Diameters 3/8” to 4”
Lengths ½” to 6”
Forming Operations
There are three phases to making a bottle once the gob leaves the feeder:
1. Delivery Equipment2. Blank Side of the Forming Machine3. Mold Side of the Forming Machine
Delivery Equipment
Scoop:Routes gob to section that is ready
Trough:Routes gob to proper deflector
Deflector:Provides control of path of falling gob for exact alignment in center of blank.
Gob delivered into the blank at 1300 ºF
Gob enters the delivery system at 1700 ºF
Forming Machine12 Section Quad
On the Windsor machines,12 Individual Sections produce 4 bottles at each section
There are 4 cavities in each section. Each cavity hasa unique number.
Forming• The gob is delivered into the blank mold side of the
machine or the rear of the machine and is formed into a parison.
• The parison will be formed by either the Press and Blow or the Blow and Blow process.
• During the forming cycle, lubrication is manually applied to the blank molds and blow molds.
Glasshouse Terms:• The “Parison” is sometimes called the “Blank”.• The technical name for the “Press and Blow”
operation is “NNPB” - Narrow Neck Press and Blow• Applying lubrication to the molds is called “doping”.
A parison is a specifically shaped formation of glass which will be blow up like a balloon in the blow mold to form the bottle.
A parison has the following features:
What is a Parison?
FinishHollow insideCooler skin or enamel on its
outer surface
Temperature of 1300 degrees F on its outer skin.
The same amount of glass as the container it will produce
Parisons are formed on the blank side of an I.S. machine from the gob
Parisons greatly differ in shape for each process and are a precise shape for each type of bottle
Parisons are created in three seconds for a typical 12 oz. container and are just barely able to hold their shape
Bottle Forming Cycle
Narrow Neck Press and Blow Process
1) Gob Delivery
2) Start Press
3) Press4) Plunger
Down
5) Parison Reheat
6) Transfer to Blow Mold - Reheat
7) Parison Reheat and
Run
8) Final Blow and Vacuum
9) Bottle Takeout
10) Bottle Cooling
Parison Formation
Press and Blow Process
1. Gob entry
2. Start Press
3. Full Press
Parison Formation
Parison
Start transfer
Container Formation
Parison transfer to mold
Mold closes
Compressed air applied
Start pickup
Container Cooling
Pickup and placement on cooling pad
Cooling pad
Fan air applied
Container cooling and transfer to conveyor cooling pad
Cooling pad
Container transfer into annealing lehr
Tin spray coating application
Annealing lehr
• Total time required to produce a container varies, but beer and soda bottles take approximately 10 seconds.
• Each section can produce 1 to 4 bottles simultaneously.
• Machines may have anywhere from 4 to 16 sections.
• Depending on container size and shape, production speed may be as fast as 700 containers per minute.
Elements of an I.S. machine• Individual sections on the forming machine allows the
ability to take one or more sections out of production for repairs without removing the other sections from producing containers for the customer.
Between the discharge from the forming machine and entry into the lehr to begin the annealing process, the first part of a two part surface treatment is applied to the container.
Annealing & Surface Treatment
After discharge from the forming machine, the bottle must be annealed. Annealing is thecontrolled removal of heat from the glass container
1) Surface Treatment protects the outside of the glass container by applying a lubricious (slick) surface on the outside of the container.
2) Surface Treatment is applied in two stages:Hot End: Tin oxide is vaporized onto the container
after leaving the forming machine but prior to entering the lehr.
Cold End: Polyethylene is sprayed onto the bottlesat the lehr discharge.
Surface Treatment
Surface TreatmentHot End Application
Tin is vaporized onto the bottles.
Annealing Lehr Cross sectional view
Heating zones Cooling zones
Typical annealing temperature curve
800
400
0
ºF
1200
Annealing point
Annealing The Glass Container
What is the purpose of annealing?• To relieve internal stresses in
the glass that are a result of uneven cooling of glass container during the forming process.
• The outer surface of the container cools fast while inner surface cools slowly, creating the stresses.
Owens-Brockway Glass Containers Inc.Owens-Brockway Glass Containers Inc..
Owens-Illinois
Annealing Lehr Cross sectional view
Heating zones Cooling zones
Typical annealing temperature curve
800
400
0
ºF
1200Annealing point
How does the lehr anneal the glass?• Reheats the glass above 1050 ºF and holds
this temperature until temperatures inside and outside the container equalize. After that, it slowly cools the container back to room temperature.
How long does this preheating and slow cooling process take?
• Depends upon the size and shape of the container
• Times vary from 20 minutes to 90 minutes.
Annealing The Glass Container
Annealing
1) Samples are obtained immediately prior to the overhead sprays to check annealing in the “Polariscope”
2) Annealing is measured in gradients of 1-5 “discs.”
Lehr Discharge Polariscope
Annealing Strain Discs
Surface TreatmentCold End Application
Polyethylene is sprayed between the rows of bottles.
Backup sprays are also available should the first unit fail to applytreatment. A diffusion hood is used to keep spray from the bottom backup unit reaching the finish of the bottle.
Surface TreatmentSpray Head Location
Spray headmust be below finish.
Diffusion hood airflow must be sufficientto keep treatment off of the finish.
Lehr conveyor mat
InspectionAutomatic Bottle Inspection
•100 % of the glass containers are inspected in a series of sophisticated machines called FP’s or FPX’s. •Data is collected and monitored to allow ready access to trend analysis and defect detection.
Palletizing
Palletizing Methods
CARTONS
Various types of corrugated packages
BULK
Bottles are placed onto tier sheetsand stretch wrapped with plastic.
QUESTIONS?