Upload
ukissmeow
View
215
Download
0
Embed Size (px)
Citation preview
7/23/2019 Glass Packaging Report
1/104
Glass for Packaging
Castillo, A. l Evaristo l Mariano l San Miguel l Tagapan l Vinluan
5ChE - A
7/23/2019 Glass Packaging Report
2/104
What is a glass?
Glass is an amorphous (non-crystalline) solid which is
often transparent and has widespread practical,
technological, and decorative usage in things like window
panes, tableware, and optoelectronics
Simpler: a hard, brittle substance, typically
transparent or translucent, made by fusingsand with soda, lime, and sometimes other
ingredients and cooling rapidly. It is used to
make windows, drinking containers, and
other articles
7/23/2019 Glass Packaging Report
3/104
PREHISTORICTIME
7/23/2019 Glass Packaging Report
4/104
7/23/2019 Glass Packaging Report
5/104
5000 BC
7/23/2019 Glass Packaging Report
6/104
7/23/2019 Glass Packaging Report
7/104
3500-500 BC
7/23/2019 Glass Packaging Report
8/104
7/23/2019 Glass Packaging Report
9/104
1000 AD
7/23/2019 Glass Packaging Report
10/104
7/23/2019 Glass Packaging Report
11/104
7/23/2019 Glass Packaging Report
12/104
7/23/2019 Glass Packaging Report
13/104
7/23/2019 Glass Packaging Report
14/104
7/23/2019 Glass Packaging Report
15/104
7/23/2019 Glass Packaging Report
16/104
1291
7/23/2019 Glass Packaging Report
17/104
7/23/2019 Glass Packaging Report
18/104
1674
7/23/2019 Glass Packaging Report
19/104
George Ravenscroft
7/23/2019 Glass Packaging Report
20/104
1870- First Semi-Bottling
machine is created
7/23/2019 Glass Packaging Report
21/104
1904
7/23/2019 Glass Packaging Report
22/104
7/23/2019 Glass Packaging Report
23/104
7/23/2019 Glass Packaging Report
24/104
Type II glass containers are made
commercial soda lime glass that has bee
alkalized to obtain a great improveme
chemical resistance by treating the in
surfaces at a high temperature to eat awaalkali on or near the glass surfaces.
undesirable characteristic of Type II Glass i
the treating etches the surface, causing a fr
appearance.
7/23/2019 Glass Packaging Report
25/104
Type III glass bottles and containers are made
of untreated commercial soda-lime glass and
has average or somewhat above average
chemical resistance. It is the most common in
use and is compatible with most items such as:
food; beverages; common chemicals, etc
7/23/2019 Glass Packaging Report
26/104
Generally recognized as safe (GRAS) is an
American Food and Drug Administration (FDA
designation that a chemical or substance added
to food is considered safe by experts, and so is
exempted from the usual Federal Food, Drug
and Cosmetic Act (FFDCA) food additive
tolerance requirements.
7/23/2019 Glass Packaging Report
27/104
RAW MATERIALS OF GLASS
7/23/2019 Glass Packaging Report
28/104
SAND
Silicon Dioxide (SiO2) [Main Component]
Melting Temperature: 1700 deg C (3090 deg
7/23/2019 Glass Packaging Report
29/104
SODA ASHSodium Carbonate (Na2CO3)Extracted on sodium-rich water source.
7/23/2019 Glass Packaging Report
30/104
Limestone/DolomiteLimestone: CaCO3Dolomite: CaMg(CO3)2
Used for mixing quality for glass.
7/23/2019 Glass Packaging Report
31/104
CulletRecycled/broken/waste glass that is used for glass making
7/23/2019 Glass Packaging Report
32/104
PRODUCTION PROCESSMARIANO, VAUGHN
7/23/2019 Glass Packaging Report
33/104
STEPS1. BATCHING
2. MELTING
3. FEEDERS
4. FORMING
5. ANNEALING
6. INSPECTION
7/23/2019 Glass Packaging Report
34/104
STEP 1 - BATCHINGRaw materials are delivered to the batch house.
It is where mixing process of different percentage of raw materials are done. (on the manufacturer)
Cullet is introduced to reduce temperature required for melting.
7/23/2019 Glass Packaging Report
35/104
STEP 2 - MELTINGThe batch is continuously fed on the furnace.
Approximately 1565 deg C to melt into a molten glass mixture.
7/23/2019 Glass Packaging Report
36/104
STEP 3 - FEEDERSThe product from the furnace enters to an orifice ring and cut by shearsperfectly elongated cylinders of glass (gob).
7/23/2019 Glass Packaging Report
37/104
STEP 4 - FORMINGPRESS AND BLOW
The cut gob falls, and using gravitational force, then it reaches to the moulders.
A metal plunger presses the gob into blank mold (called the parison).
The parison is moved into the final mold where it is blown into the mould to assume fof glass bottle.
7/23/2019 Glass Packaging Report
38/104
STEP 4 - FORMINGBLOW AND BLOW
The gob is forced into a blank mould using compressed air to push the gob into place.
Now in a parison, is then flipped into a corresponding final mould where it blown agaiinterior side of the glass container.
Glass bottles of varying neck size and thickness can be used using blow-by-blow forma
7/23/2019 Glass Packaging Report
39/104
STEP 5 ANNEALINGOnce formation is complete, some bottles may suffer from stress as a result of unequarates.
Annealing is the process where the bottles are preheated again in the oven and cool gcontainers to rectify stress and make bottle stronger.
7/23/2019 Glass Packaging Report
40/104
STEP 6 - INSPECTIONInspection is done by combination of automated and mechanical checkup of bensure integrity of the final product.
Common checks areCracks on the glass.Stones that is not formed properly on the furnace.
7/23/2019 Glass Packaging Report
41/104
7/23/2019 Glass Packaging Report
42/104
Glass Properties
Strong and durable packaging that can be formed in wide va
shape
Excellent moisture and gas barrier
Fragile and easily breakable
Inert and biologically inactive
Nonporous and impermeable Glass has an almost zero rate of chemical interactions
100% recyclable and safest packaging
7/23/2019 Glass Packaging Report
43/104
Glass Colorization
Color can distinguish a glass container, shield its contents fro
unwanted ultraviolet rays or create a variety within a brand
Decolorization the addition of selenium and cobalt in propproportions to yield a gray glass that appears colorless
7/23/2019 Glass Packaging Report
44/104
7/23/2019 Glass Packaging Report
45/104
Glass Colors
Amber Glass The most common colored glass, and is produced by adding
iron, sulfur, and carbon.
Amber is a reduced glass because of the relatively high levcarbon used.
It absorbs nearly all radiation consisting of wavelengths sho450 nm, offering excellent protection from ultraviolet radiat
Used in beers, medicines and chemicals
7/23/2019 Glass Packaging Report
46/104
Glass Colors
Green Glass Green Glass is made by adding non-toxic Chrome Ox
the higher the concentration, the darker the color.
Green glass can be either oxidized, such as EmeraldGreen or Georgia green, or reduced, as with Dead Legreen.
7/23/2019 Glass Packaging Report
47/104
Glass Colors
Blue Glass Blue glass is created by adding cobalt oxide, a colorant so po
that only a few parts per million is needed to produce a lighcolor such as the shade used for certain bottled waters.
Blue glasses are nearly always oxidized glasses. However, a l
green glass can be produced using only iron and carbon andthe sulfur, making it a reduced blue.
f
7/23/2019 Glass Packaging Report
48/104
Types of glass
Type I- Borosilicate Glass Composed of silica (70-80%), boric oxide (7-13%) and smaller amounts of the alkalis
aluminum and potassium oxides) such as 4-8% of Na2O and K2O and 2-7% aluminu
Addition of 6% boron provides a greater resistance to thermal shock and hydrolytic
Least reactive glass available for containers
Greater resistance to thermal shock and changes and chemical corrosion
It can be used for all applications and is most commonly used to pack water for injebuffered products, chemicals, sensitive lab samples.
For more sensitive pharmaceuticals such as parenteral or blood products (ampoule Used to pack products which are alkaline or will become alkaline prior to their expir
f l
7/23/2019 Glass Packaging Report
49/104
Types of glass
Type II-Dealkalized or Treated Soda Lime Glass
Has higher level of sodium hydroxide
It is less chemical resistant that Type I but is a good alkaresistant
It is treated to remove surface alkali to prevent the wea
(or blooming) of empty bottles. The treatment is called treatment which uses sulfur dioxide or ammonia sulfate
T f l
7/23/2019 Glass Packaging Report
50/104
Types of glass
Type III- Conventional
Soda Lime Glass It has a low hydrolytic
resistance
Acceptable in packaging somedry powders which aresubsequently dissolved to make
solutions or buffers Suitable for packaging liquid
formulations that prove to beinsensitive to alkali
T f l
7/23/2019 Glass Packaging Report
51/104
Types of glass
Type IV- General Purpose Soda Lime Glass
Is used for non-parenteral applications where chemical duraheat shock are not factors
Frequently used for capsules, tablets and topical products.
7/23/2019 Glass Packaging Report
52/104
QUALITY CONTROLCASTILLO, ARLYN
Gl C iti C t l M th d
7/23/2019 Glass Packaging Report
53/104
Glass Composition Control Methods
Density
Density is defined as weight per unit volume. It is measuredcomparison to a known standard using a sink-float techniqucan determine the density to the nearest 0.0002 grams per centimeter.
7/23/2019 Glass Packaging Report
54/104
7/23/2019 Glass Packaging Report
55/104
Glass Performance and Testing
7/23/2019 Glass Packaging Report
56/104
Glass Performance and Testing
b. Water Attack Test
This test is used only with containers that have been exposed to dioxide fumes under controlled humidity conditions.
The principle involved in the water attack test is to determine whalkali leached form the surface of a container is within the specifor not.
The amount of acid that is necessary to neutralize the released a
the surface is estimated, the leaching of alkali is accelerated usintemperature for a specified time.
Methyl red indicator is used to determine the end point. The babase titration.
Glass Performance and Testing
7/23/2019 Glass Packaging Report
57/104
Glass Performance and Testing
2. Vertical Load Strength
Forces of nature might be producedduring capping or through stackingproducts on top of each other.
Used Universal Testing Machine tohelp ensure glass containers haveadequate vertical load strength
The shoulder design is important inminimizing the breakage during highspeed filling and sealing operations.
Glass Performance and Testing
7/23/2019 Glass Packaging Report
58/104
Glass Performance and Testing
3. Impact Testing Using industry standard Pendulum
Impact Tester, to help ensure glasscontainers have adequate impactresistance
4. Thermal Shock Hot-fill or heat treated glassware can
be tested using empirical testingprocedures to ensure the product is fitfor the intended purpose
Sudden heat leads to surfacecompression and internal tension
Glass Performance and Testing
7/23/2019 Glass Packaging Report
59/104
Glass Performance and Testing
5. Coating Performance
Assessment of surface protection can be carried out by use tables and hot and coating technology. The longevity of the performance can be assessed using line simulator, whereby bottle abrasion damage which may be expected to occur online can be replicated and the subsequent damage of the co
tested.
Glass Performance and Testing
7/23/2019 Glass Packaging Report
60/104
Glass Performance and Testing
6. Internal Pressure Resistance
Carbonated beverage bottles need tobe able to withstand without failurethe pressure produced by theircontents over long periods.
Because the bottle is likely to beprocessed in boiling water or in
pressurized hot water
7. Residual Strain
Measurement of annealing stress
Glass Defects are classified as
7/23/2019 Glass Packaging Report
61/104
Glass Defects are classified as
Critical-those that are hazardous to the user and those that
container completely unusable Major- those that materially reduce the usability of the cont
its contents
Minor-those that do not affect the usability of the containedetract from its appearance or acceptability to the custome
7/23/2019 Glass Packaging Report
62/104
ADVANTANGES ANDDISADVANTAGESEVARISTO, CARLA RAE
Advantages of Glass Packaging
7/23/2019 Glass Packaging Report
63/104
Advantages of Glass Packaging
glass is able to withstand heat treatments
Glass is nonporous and impermeable thus it does not react with food
it is rigid and protects the food from crushing and bruising
it is impervious to moisture, gases, odors and microorganisms
it is re-usable, re-sealable and recyclable
it is transparent, allowing products to be displayed.
7/23/2019 Glass Packaging Report
64/104
7/23/2019 Glass Packaging Report
65/104
7/23/2019 Glass Packaging Report
66/104
7/23/2019 Glass Packaging Report
67/104
7/23/2019 Glass Packaging Report
68/104
7/23/2019 Glass Packaging Report
69/104
Disadvantages of Glass Packaging
7/23/2019 Glass Packaging Report
70/104
Disadvantages of Glass Packaging
glass is heavier; higher transport costs
it is easy to fracture, scratch and break
potentially serious hazards may arise from glass
splinters or fragments in the food.
7/23/2019 Glass Packaging Report
71/104
DESIGN AND HANDLINGVINLUAN, JUSTIN
7/23/2019 Glass Packaging Report
72/104
Sustainable design considerations
7/23/2019 Glass Packaging Report
73/104
g
Efficiency optimization of label
Accessibility - lids
Recycling
Minimize food waste
Consumer labelling
7/23/2019 Glass Packaging Report
74/104
Glass packaging transport/handling
7/23/2019 Glass Packaging Report
75/104
p g g p g
Substantial requirements on packaging systems
Smartcap from Loadhog Safe handling for everyday use
7/23/2019 Glass Packaging Report
76/104
GLASS RECYCLINGSAN MIGUEL, ANDRE
Glass can live FOREVER!!
7/23/2019 Glass Packaging Report
77/104
SPEND A MILLION YEARS IN A
LANDFILL BEFORE IT WILL BEGINTO DECOMPOSE
CAN BE RECYCLED AT
AMOUNT OF TIMES CTO THE MILLION YWASTE
Cullet
7/23/2019 Glass Packaging Report
78/104
Crushed post-consumer glass containers
Recycled glass feed Used in different mix/percentage depending on quality
Cullet
7/23/2019 Glass Packaging Report
79/104
Quality is based on the amount of contaminants
If the cullet is of sufficient quality then glass can cont90% recycled content; the approximate tolerancedifferent glass colors for the inclusion of cullet are:
Flint: 5060% cullet Amber: up to 90% cullet
Green: up to 90% cullet
Other use of cullet (Source of Market)
7/23/2019 Glass Packaging Report
80/104
HIGH QUALITY CULLET
- abrasives, aggregate substitute, bead manufacturing,decorative applications, fiberglass, frictionators (match strikesurfaces), and fluxes in metal foundry work.
LOW QUALITY CULLET
- manufacture of fiberglass insulation, roadbed aggregasafety reflective beads, and decorative tile.
Why recycle glass?
7/23/2019 Glass Packaging Report
81/104
UNMATCHED ENVIRONMENTAL and PRODU
BENEFITS Saves raw materials
Lessens the demand for energy
Cuts CO2 emissions
Extends furnace life No by-products produced
SAVES RAW MATERIALS
7/23/2019 Glass Packaging Report
82/104
According to Glass Packaging Institute (GPI), for every ton of cused..
1. 1,300 pounds of sand
2. 410 pounds of soda ash
3. 380 pounds of limestone
4. 180 pounds of feldspar
are conserved.
LESSENS THE DEMAND FOR ENERGY
7/23/2019 Glass Packaging Report
83/104
Energy costs drop about 2-3% for every 10% cullet used in the
manufacturing process. (GPI)
Use of cullet eliminates the energy and other impacts that wobeen required to mine and process an equivalent amount of vmaterial inputs.
Eliminate the diversion of glass to landfill, leading to a decreaenergy use and global warming potential.
CUTS CO2 EMISSION
7/23/2019 Glass Packaging Report
84/104
For every six tons of recycled container glass used, a ton
dioxide, a greenhouse gas, is reduced. A relative 10% increasreduces particulates by 8%, nitrogen oxide by 4%, and sulfur10%. (GPI)
Smelting virgin materials to manufacture glass packaging also
the direct emission of carbon dioxide (CO2) due to thereactions taking place
EXTENDS FURNACE LIFE
7/23/2019 Glass Packaging Report
85/104
Container glass furnaces are generally designed to melt large
of glass over a continuous period of more than 20 years anoutput from 150 tons of glass per day to over 600 tons of glas
Including cullet in the manufacturing mix makes it less corlowers the melting temperature (from 2800 to 2600F.),
furnace life. (GPI)
NO BY-PRODUCTS PRODUCED
7/23/2019 Glass Packaging Report
86/104
Glass recycling is a closed-loop system, creating no additiona
by-products. (GPI)
Much of glass container recycling is in a closed loop, which ma glass container becomes the same product again and again.
The endless recycling of glass back to its original use withoquality or purity is the true definition of a recyclable material
THE DRAWBACK - CONTAMINATION
7/23/2019 Glass Packaging Report
87/104
Glass manufacturing is sensitive to impurities such as: ceram
(e.g. aluminium tamper-evident rings or steel jar lids), nonglass types, plastics, cobalt blue glass, and some metal-b(which may be used for on glass printing, although uncommo
According to GPI
7/23/2019 Glass Packaging Report
88/104
Contamination from non-container glass, metal, gravel, an
occur when glass containers are set out for recycling, duringand processing, or in transit.
Unwanted items in cullet:
decrease the value of recovered glass
increase recycling costs
slow container production
reduce glass quality
damage glass manufacturing equipment
SORTING BY COLOR
7/23/2019 Glass Packaging Report
89/104
Color sorting makes a difference. Glass manufacturers are limamount of mixed color-cullet (called "3 mix") they camanufacture new containers. Separating recycled containecolor allows the industry to ensure that new bottles matchstandards required by glass container customers.
The recycle symbol
7/23/2019 Glass Packaging Report
90/104
VS
7/23/2019 Glass Packaging Report
91/104
7/23/2019 Glass Packaging Report
92/104
7/23/2019 Glass Packaging Report
93/104
7/23/2019 Glass Packaging Report
94/104
LIGHTWEIGHTINGSAN MIGUEL, ANDRE
LIGHTWEIGHTING
7/23/2019 Glass Packaging Report
95/104
An industry term referring to ways to strengthen glass thrsurface treatments and better designs, withoutimprovements in material reduction.
It has become one of the single most important innovations iindustry.
Improved technology has led to lighter weight glass containerremarkably strong and safe.
LIGHTWEIGHTING
7/23/2019 Glass Packaging Report
96/104
Sample weight reduction since 1985
7/23/2019 Glass Packaging Report
97/104
Glass Product % Reduced
7 oz. Beer 30%12 oz. Long Neck Beer 24%
1L Liquor 23%
16 oz. Juice 22%
Vinegar bottle 32%
14 oz. Catsup bottle 32%
375mL Flask 27%
BENEFITS OF LIGHTWEIGHTING
7/23/2019 Glass Packaging Report
98/104
Manufacturers are able to save on raw materials and melti
Production lines can run at a much faster pace because theglass per container and less energy needed for cooling.
The introduction of the Narrow Neck Press and Blow (NNPBprocess is widely credited with helping to reduce the overalmanufacturing weight and thickness of glass containers
Since 1985, the glass packaging industry has reduced the wglass containers and improved productivity by as much as 1percent
BENEFITS OF LIGHTWEIGHTING
7/23/2019 Glass Packaging Report
99/104
In the manufacturing process, the bottle is pressed into its shape while still in the blank mold.
Manufacturers are able to exert greater control over the dethickness of a glass container.
Excess glass from the neck and other parts of the bottle whthickness is not critical is shifted into areas where it is neede
The result is a reduction in the amount of glass required in
container and more uniform glass distribution throughout tcontainer.
RIGHTWEIGHTING
7/23/2019 Glass Packaging Report
100/104
A process of packaging design and produc
optimise packaging weight, whilst taking intothe requirements of all stakeholders in thechain, including manufacturers, brand ownersretailers, consumers and the environment.
7/23/2019 Glass Packaging Report
101/104
GLASS PACKAGING INDUSTRYTHE PHILIPPINESSAN MIGUEL, ANDRE
GLASS PRODUCERS IN THE PHILIPPINES
7/23/2019 Glass Packaging Report
102/104
SAN MIGUEL YAMAMURA PACKAGING
CORPORATION (SMYPC)Manufacturer of plastic and metal closures, corrugated cartoontainers, collapsible tubes, plastic cases and pressed glassw
Glass plant: Manila Glass Plant (1949)
Mandaue Glass Plant (1968)
GLASS PRODUCERS IN THE PHILIPPINES
7/23/2019 Glass Packaging Report
103/104
ASIA BREWERY
Manufacturer of beer and commercial bottles, rigid plastic bottles, closuates
Glass Plant Calamba Glass Plant
ARCYA GLASS
produces a diverse line of flint (clear) glass containers for a wideproducts, including alcoholic beverages, carbonated soft drinkcondiments and food products.
Glass Plant Calamba Glass Plant
GLASS PRODUCERS IN THE PHILIPPINES
7/23/2019 Glass Packaging Report
104/104
Unlipack Packaging Philippines
Child Company of Astro BottlesProducts: Bottle and Container Supplier, Packaging Supplies & ECosmetics & Beauty Supply , Food & Beverage Service & Distributi
Location: Tondo, Manila
SAINTS AND BRANCH CORPORATIONLocation: Paraaque