glass packaging report

7/23/2019 Glass Packaging Report

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Glass for Packaging

Castillo, A. l Evaristo l Mariano l San Miguel l Tagapan l Vinluan

5ChE - A


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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


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PREHISTORICTIME


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5000 BC


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3500-500 BC


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1000 AD


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1291


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1674


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George Ravenscroft


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1870- First Semi-Bottling

machine is created


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1904


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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.


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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


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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.


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RAW MATERIALS OF GLASS


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SAND

Silicon Dioxide (SiO2) [Main Component]

Melting Temperature: 1700 deg C (3090 deg


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SODA ASHSodium Carbonate (Na2CO3)Extracted on sodium-rich water source.


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Limestone/DolomiteLimestone: CaCO3Dolomite: CaMg(CO3)2

Used for mixing quality for glass.


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CulletRecycled/broken/waste glass that is used for glass making


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PRODUCTION PROCESSMARIANO, VAUGHN


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STEPS1. BATCHING

2. MELTING

3. FEEDERS

4. FORMING

5. ANNEALING

6. INSPECTION


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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.


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STEP 2 - MELTINGThe batch is continuously fed on the furnace.

Approximately 1565 deg C to melt into a molten glass mixture.


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STEP 3 - FEEDERSThe product from the furnace enters to an orifice ring and cut by shearsperfectly elongated cylinders of glass (gob).


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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.


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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


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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.


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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.


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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


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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


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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


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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.


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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


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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


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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


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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

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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.


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QUALITY CONTROLCASTILLO, ARLYN

Gl C iti C t l M th d


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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.


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Glass Performance and Testing


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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.



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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.



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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



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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.



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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


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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


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ADVANTANGES ANDDISADVANTAGESEVARISTO, CARLA RAE

Advantages of Glass Packaging


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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.


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Disadvantages of Glass Packaging


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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.


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DESIGN AND HANDLINGVINLUAN, JUSTIN


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Sustainable design considerations


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g

Efficiency optimization of label

Accessibility - lids

Recycling

Minimize food waste

Consumer labelling


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Glass packaging transport/handling


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p g g p g

Substantial requirements on packaging systems

Smartcap from Loadhog Safe handling for everyday use


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GLASS RECYCLINGSAN MIGUEL, ANDRE

Glass can live FOREVER!!


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SPEND A MILLION YEARS IN A

LANDFILL BEFORE IT WILL BEGINTO DECOMPOSE

CAN BE RECYCLED AT

AMOUNT OF TIMES CTO THE MILLION YWASTE

Cullet


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Crushed post-consumer glass containers

Recycled glass feed Used in different mix/percentage depending on quality

Cullet


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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)


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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?


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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


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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


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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


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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


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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


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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


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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


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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


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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


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VS


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LIGHTWEIGHTINGSAN MIGUEL, ANDRE

LIGHTWEIGHTING


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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


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Sample weight reduction since 1985


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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


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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


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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


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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.


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GLASS PACKAGING INDUSTRYTHE PHILIPPINESSAN MIGUEL, ANDRE

GLASS PRODUCERS IN THE PHILIPPINES


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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)



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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



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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

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