Glass Packaging Report

Glass for Packaging Castillo, A. l Evaristo l Mariano l San Miguel l Tagapan l Vinluan 5ChE - A

What is a glass? Simpler: a hard, brittle substance, typically or translucent, madesolid by fusing Glass is transparent an amorphous (non-crystalline) which is sand with soda, lime, and sometimes other often transparent and has widespread practical, ingredients and coolingusage rapidly. It is used technological, and decorative in things liketo window make windows, drinking containers, and panes, tableware, and optoelectronics other articles

PREHISTORIC TIME

5000 BC

3500-500 BC

1000 AD

13th Century

1291

1674

George Ravenscroft

1870- First Semi-Bottling machine is created

1904

Type I glass bottles are made from borosilicate, which has a highly resistant composition and releases the least amount of alkali. It is commonly used for pharmaceutical or fine chemical products that are sensitive to PH changes.

Type II glass containers are made from commercial soda lime glass that has been dealkalized to obtain a great improvement in chemical resistance by treating the interior surfaces at a high temperature to eat away the alkali on or near the glass surfaces. The undesirable characteristic of Type II Glass is that the treating etches the surface, causing a frosted appearance.

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

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.

RAW MATERIALS OF GLASS

• Silicon Dioxide (SiO2) [Main Component] • Melting Temperature: 1700 deg C (3090 deg F)

SAND

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

Limestone/Dolomite Limestone: CaCO3 Dolomite: CaMg(CO3)2 Used for mixing quality for glass.

Cullet Recycled/broken/waste glass that is used for glass making

PRODUCTION PROCESS MARIANO, VAUGHN

STEPS 1. 2. 3. 4. 5. 6.

BATCHING MELTING FEEDERS FORMING ANNEALING INSPECTION

STEP 1 - BATCHING Raw materials are delivered to the batch house. It is where mixing process of different percentage of raw materials are done. (Depending on the manufacturer) Cullet is introduced to reduce temperature required for melting.

STEP 2 - MELTING The batch is continuously fed on the furnace. Approximately 1565 deg C to melt into a molten glass mixture.

STEP 3 - FEEDERS The product from the furnace enters to an orifice ring and cut by shears to produce perfectly elongated cylinders of glass (gob).

STEP 4 - FORMING PRESS 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 final dimension of glass bottle.

STEP 4 - FORMING BLOW 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 again, to form the interior side of the glass container. Glass bottles of varying neck size and thickness can be used using blow-by-blow formation.

STEP 5 – ANNEALING Once formation is complete, some bottles may suffer from stress as a result of unequal cooling rates. Annealing is the process where the bottles are preheated again in the oven and cool glass containers to rectify stress and make bottle stronger.

STEP 6 - INSPECTION Inspection is done by combination of automated and mechanical checkup of bottles to ensure integrity of the final product. Common checks are Cracks on the glass. Stones that is not formed properly on the furnace.

GLASS PROPERTIES AND SPECIFICATIONS CASTILLO, ARLYN

Glass Properties • Strong and durable packaging that can be formed in wide variety of 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

Glass Colorization • Color can distinguish a glass container, shield its contents from unwanted ultraviolet rays or create a variety within a brand category. • Decolorization – the addition of selenium and cobalt in proper proportions to yield a gray glass that appears colorless

Glass Colors Amber Glass • The most common colored glass, and is produced by adding together iron, sulfur, and carbon. • Amber is a “reduced” glass because of the relatively high level of carbon used. • It absorbs nearly all radiation consisting of wavelengths shorter than 450 nm, offering excellent protection from ultraviolet radiation • Used in beers, medicines and chemicals

Glass Colors Green Glass • Green Glass is made by adding non-toxic Chrome Oxide; the higher the concentration, the darker the color. • Green glass can be either oxidized, such as Emerald Green or Georgia green, or reduced, as with Dead Leaf green.

Glass Colors Blue Glass • Blue glass is created by adding cobalt oxide, a colorant so powerful that only a few parts per million is needed to produce a light blue color such as the shade used for certain bottled waters. • Blue glasses are nearly always oxidized glasses. However, a light bluegreen glass can be produced using only iron and carbon and omitting the sulfur, making it a reduced blue.

Types of glass Type I- Borosilicate Glass • Composed of silica (70-80%), boric oxide (7-13%) and smaller amounts of the alkalis( sodium, aluminum and potassium oxides) such as 4-8% of Na2O and K2O and 2-7% aluminum oxide. • Addition of 6% boron provides a greater resistance to thermal shock and hydrolytic attack. • 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 injection, UNbuffered products, chemicals, sensitive lab samples. • For more sensitive pharmaceuticals such as parenteral or blood products (ampoules and vials) • Used to pack products which are alkaline or will become alkaline prior to their expiration date.

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 alkali resistant • It is treated to remove surface alkali to prevent the weathering (or blooming) of empty bottles. The treatment is called sulfur treatment which uses sulfur dioxide or ammonia sulfate

Types of glass Type III- Conventional Soda Lime Glass • It has a low hydrolytic resistance • Acceptable in packaging some dry powders which are subsequently dissolved to make solutions or buffers • Suitable for packaging liquid formulations that prove to be insensitive to alkali

Types of glass Type IV- General Purpose Soda Lime Glass • Is used for non-parenteral applications where chemical durability and heat shock are not factors • Frequently used for capsules, tablets and topical products.

QUALITY CONTROL CASTILLO, ARLYN

Glass Composition Control Methods Density • Density is defined as weight per unit volume. It is measured by comparison to a known standard using a sink-float technique, which can determine the density to the nearest 0.0002 grams per cubic centimeter.

Glass Composition Control Methods Softening Point • The softening point for composition control is defined as the temperature at which a fiber of specified length and diameter will elongate at a rate of 1mm per minute, or the temperature at which the log of the viscosity equals 7.65.

Glass Performance and Testing 1. Chemical Resistance Test a. Powdered Glass Test • From the glass containers, alkaline constituents (oxides of sodium, potassium, calcium, aluminum, etc.) are leached into purified water under conditions of elevated temperatures. • The basic analysis is acid-base titration using methyl red indicator.

Glass Performance and Testing •

• • •

b. Water Attack Test This test is used only with containers that have been exposed to sulfur dioxide fumes under controlled humidity conditions. The principle involved in the water attack test is to determine whether the alkali leached form the surface of a container is within the specified limits or not. The amount of acid that is necessary to neutralize the released alkali from the surface is estimated, the leaching of alkali is accelerated using elevated temperature for a specified time. Methyl red indicator is used to determine the end point. The basic is acidbase titration.

Glass Performance and Testing 2. Vertical Load Strength • Forces of nature might be produced during capping or through stacking products on top of each other. • Used Universal Testing Machine to help ensure glass containers have adequate vertical load strength • The shoulder design is important in minimizing the breakage during high speed filling and sealing operations.

Glass Performance and Testing 3. Impact Testing • Using industry standard Pendulum Impact Tester, to help ensure glass containers have adequate impact resistance

4. Thermal Shock • Hot-fill or heat treated glassware can be tested using empirical testing procedures to ensure the product is fit for the intended purpose • Sudden heat leads to surface compression and internal tension

Glass Performance and Testing 5. Coating Performance • Assessment of surface protection can be carried out by use of slip tables and hot and coating technology. The longevity of the coating performance can be assessed using line simulator, whereby bottle to bottle abrasion damage which may be expected to occur on a filling line can be replicated and the subsequent damage of the container tested.

Glass Performance and Testing 6. Internal Pressure Resistance • Carbonated beverage bottles need to be able to withstand without failure the pressure produced by their contents over long periods. • Because the bottle is likely to be processed in boiling water or in pressurized hot water

7. Residual Strain • Measurement of annealing stress

Glass 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

ADVANTANGES AND DISADVANTAGES EVARISTO, CARLA RAE

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.

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.

DESIGN AND HANDLING VINLUAN, JUSTIN

Sustainable design considerations • Efficiency – optimization of label • Accessibility - lids • Recycling • Minimize food waste • Consumer labelling

Glass packaging transport/handling • Substantial requirements on packaging systems • Smartcap from Loadhog • Safe handling for everyday use

GLASS RECYCLING SAN MIGUEL, ANDRE

Glass can live FOREVER!! • SPEND A MILLION YEARS IN A • CAN BE RECYCLED AT INFINITE LANDFILL BEFORE IT WILL BEGIN AMOUNT OF TIMES COMPARED TO DECOMPOSE TO THE MILLION YEARS OF WASTE

Cullet • Crushed post-consumer glass containers • Recycled glass feed • Used in different mix/percentage depending on quality

Cullet Quality is based on the amount of contaminants If the cullet is of sufficient quality then glass can contain up to 90% recycled content; the approximate tolerances of the different glass colors for the inclusion of cullet are: • Flint: 50–60% cullet • Amber: up to 90% cullet • Green: up to 90% cullet

Other use of cullet (Source of Market) HIGH QUALITY CULLET - abrasives, aggregate substitute, bead manufacturing, decorative applications, fiberglass, frictionators (match striker surfaces), and fluxes in metal foundry work. LOW QUALITY CULLET - manufacture of fiberglass insulation, roadbed aggregate, driving safety reflective beads, and decorative tile.

Why recycle glass? UNMATCHED ENVIRONMENTAL and PRODUCTION BENEFITS  Saves raw

materials  Lessens the demand for energy  Cuts CO2 emissions  Extends furnace life  No by-products produced

SAVES RAW MATERIALS According to Glass Packaging Institute (GPI), for every ton of cullet used….. 1. 2. 3. 4.

1,300 pounds of sand 410 pounds of soda ash 380 pounds of limestone 180 pounds of feldspar

……are conserved.

LESSENS THE DEMAND FOR ENERGY 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 would have been required to mine and process an equivalent amount of virgin material inputs. Eliminate the diversion of glass to landfill, leading to a decrease in energy use and global warming potential.

CUTS CO2 EMISSION For every six tons of recycled container glass used, a ton of carbon dioxide, a greenhouse gas, is reduced. A relative 10% increase in cullet reduces particulates by 8%, nitrogen oxide by 4%, and sulfur oxides by 10%. (GPI) Smelting virgin materials to manufacture glass packaging also results in the direct emission of carbon dioxide (CO2) due to the chemical reactions taking place

EXTENDS FURNACE LIFE Container glass furnaces are generally designed to melt large quantities of glass over a continuous period of more than 20 years and range in output from 150 tons of glass per day to over 600 tons of glass per day. Including cullet in the manufacturing mix makes it less corrosive and lowers the melting temperature (from 2800 to 2600°F.), prolonging furnace life. (GPI)

NO BY-PRODUCTS PRODUCED Glass recycling is a closed-loop system, creating no additional waste or by-products. (GPI) Much of glass container recycling is in a closed loop, which means that a glass container becomes the same product again and again. The endless recycling of glass back to its original use without loss of quality or purity is the true definition of a recyclable material.

THE DRAWBACK - CONTAMINATION Glass manufacturing is sensitive to impurities such as: ceramics, metals (e.g. aluminium tamper-evident rings or steel jar lids), non-packaging glass types, plastics, cobalt blue glass, and some metal-based inks (which may be used for on glass printing, although uncommon).

According to GPI Contamination from non-container glass, metal, gravel, and dirt can occur when glass containers are set out for recycling, during collection and 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 Color sorting makes a difference. Glass manufacturers are limited in the amount of mixed color-cullet (called "3 mix") they can use to manufacture new containers. Separating recycled container glass by color allows the industry to ensure that new bottles match the color standards required by glass container customers.

The recycle symbol

VS

LIGHTWEIGHTING SAN MIGUEL, ANDRE

LIGHTWEIGHTING An industry term referring to ways to strengthen glass through new surface treatments and better designs, without sacrificing improvements in material reduction. It has become one of the single most important innovations in the glass industry. Improved technology has led to lighter weight glass containers that are remarkably strong and safe.

LIGHTWEIGHTING

Sample weight reduction since 1985 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  Manufacturers are able to save on raw materials and melting costs  Production lines can run at a much faster pace because there is less glass per container and less energy needed for cooling.  The introduction of the Narrow Neck Press and Blow (NNPB) forming process is widely credited with helping to reduce the overall manufacturing weight and thickness of glass containers  Since 1985, the glass packaging industry has reduced the weight of glass containers and improved productivity by as much as 15 to 25 percent

BENEFITS OF LIGHTWEIGHTING  In the manufacturing process, the bottle is pressed into its initial shape while still in the blank mold.  Manufacturers are able to exert greater control over the desired thickness of a glass container.  Excess glass from the neck and other parts of the bottle where thickness is not critical is shifted into areas where it is needed most  The result is a reduction in the amount of glass required in a given container and more uniform glass distribution throughout the container.

RIGHTWEIGHTING A process of packaging design and production to optimise packaging weight, whilst taking into account the requirements of all stakeholders in the supply chain, including manufacturers, brand owners, fillers, retailers, consumers and the environment.

GLASS PACKAGING INDUSTRY IN THE PHILIPPINES SAN MIGUEL, ANDRE

GLASS PRODUCERS IN THE PHILIPPINES SAN MIGUEL YAMAMURA PACKAGING CORPORATION (SMYPC) Manufacturer of plastic and metal closures, corrugated cartons, glass c ontainers, collapsible tubes, plastic cases and pressed glasswares Glass plant: Manila Glass Plant (1949) Mandaue Glass Plant (1968)

GLASS PRODUCERS IN THE PHILIPPINES ASIA BREWERY Manufacturer of beer and commercial bottles, rigid plastic bottles, closures and cr ates Glass Plant – Calamba Glass Plant

ARCYA GLASS produces a diverse line of flint (clear) glass containers for a wide variety of products, including alcoholic beverages, carbonated soft drinks, ketchup, condiments and food products. Glass Plant – Calamba Glass Plant

GLASS PRODUCERS IN THE PHILIPPINES Unlipack Packaging Philippines Child Company of Astro Bottles Products: Bottle and Container Supplier, Packaging Supplies & Equipment , Cosmetics & Beauty Supply , Food & Beverage Service & Distribution Location: Tondo, Manila

SAINTS AND BRANCH CORPORATION Location: Parañaque