Glasss Bottles 
  Process 
 

Sand, soda ash, and limestone are weighed and mixed with other raw materials and cullet to create the batch mixture.

The furnace melts the raw materials together. Our furnaces vary in size, and can process from 80 to 500 tons of molten glass per day. Molten glass usually ranges in temperature between 2,300 and 2,800 ºF. A Furnace Control Room houses the computer which monitors and controls furnace temperature. Natural gas, oil and electricity provide the energy needed for melting and to operate the plant.

The Refiner distributes the molten glass to the forehearth. The glass temperature is now below 2,300 ºF. The forehearth brings the temperature of the molten glass to a uniform level. A Shearing and Distribution System cuts molten glass from the forehearth into uniform gobs and sends the gobs to the I.S. (Individual Section) Forming Machine where compressed air or pressure forces the molten gobs into the shape of the mold. The control system monitors and adjusts the I.S. Forming Machine speed and timing. The glass temperature drops further in the Forming Machine and is typically below 2,100 ºF. When formed glass containers leave the machine, they cross a cooling plate where they are cooled rapidly to below 900ºF. The glass has now passed from liquid to solid form.

The formed containers are loaded into an Annealing Lehr where their temperature is brought back up close to the melting point, then reduced gradually to below 900ºF. This reheating and slow cooling eliminates the stress in the containers making them stronger and shock resistant.

The Cold End sprays apply an exterior coating to strengthen the containers and reduce abrasions. Their action reduces the glass temperature further to between 225 and 275 ºF.

The Fast Cooling Section then brings container temperatures down to about 100ºF, cool enough to touch by hand.

The manufactured containers then pass through a series of instruments that physically and optically test the containers. Rejected containers are recycled back into the furnace.

Containers are then packed either by a Case Packer or a Bulk Palletizer. The Case Packer can put 6, 15, 18, 24, or 48 containers in corrugated cases for shipment. The cases are then sent to the Case Palletizer where they are stacked in a prearranged pattern. The pattern increases stability for shipment and is often determined by the customer. Containers can also be sent to a Bulk Palletizer which stacks individual containers in 5 to 15 layers, depending on the size of the container. A Strapper fits plastic bands around stacked boxes for added stability and finally the Stretch Wrap Unit covers stacked boxes with plastic wrap.

 


   

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