Transcript Forming Machine - Knudsen Beverage Consulting

MBAA Rocky Mountain District
Technical Summit
June 25, 2010
Everything’s Better in Glass
Connie Maxwell, Quality Manager
O-I Windsor, Colorado
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
Owens-Illinois, Inc.
Global Glass Industry Update
2
O-I Global Glass Profile
O-I Europe #1
O-I North America #1
•19 manufacturing plants
• 6,000 employees
• 1.2 million tons of recycled glass
•38 manufacturing plts
• 8,500 employees
• 3.0 million tons of
recycled glass
O-I Asia Pacific #1
•10 manufacturing plants
• 3,500 employees
• 0.6 million tons of recycled glass
O-I South America #1
•11 manufacturing plants
• 4,600 employees
• 0.4 million tons of recycled glass
O-I North America Facilities
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3
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5
6
7
8
9
10
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14
15
16
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18
19
Auburn, NY
Crenshaw, PA
Brockway, PA
Toano, VA
Danville, VA
Winston-Salem, NC
Atlanta, GA
Zanesville, OH
Lapel, IN
Streator, IL
Muskogee, OK
Waco, TX
Portland, OR
Oakland, CA
Tracy, CA
Los Angeles
Windsor, CO
Brampton, Ontario
Montreal, Quebec
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16
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2, 3
17
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6
4
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 Factory
Batch and Furnace
HOT END
Forming
Surface Treatment
Selecting / Inspection
COLD END
Palletizing
Carton Assembly
Shipping
Batch House
•Raw Material Unloading
–Truck or Rail
•Storage
–Individual Silos
•Batch weighing
–± 0.1 % Accuracy
•Batch Mixing
•Mixed Batch Transport
Batch composition:
1) Raw Materials
70% Sand
15% Soda Ash
12% Limestone
Plus 3% Colorants and Oxidizers
2) Cullet
Up to 50% recycled glass from internal plant sources
and recycling centers can be used. Cullet aids in fuel
efficiency and melting in the furnace.
Forming Machine
Windsor Plant
Oxygen Fueled Furnace
Exhaust Flue
Refiner
Exhaust Port
Ports (Fuel)
Doghouse
(Batch Delivery)
Alcove
Melter
Ports (Fuel)
Forehearth
Throat End Wall
Feeder
Forming Machine
Furnace Interior
Batch Delivery
Melter Area
Glass Flow
Entry into refiner / alcove
leading to forehearth
Glass Flow
Glass Formation
Approximate 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
Feeder
Forehearth
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
Glass is formed into “Gobs” by
a 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
Feeder
What is a gob?
Diameters 3/8” to 4”
Lengths ½” to 6”
A gob is a specific amount of molten glass that will
be formed into a glass container.
Forming Operations
There are three phases to making a bottle once
the gob leaves the feeder:
1.
2.
3.
Delivery Equipment
Blank Side of the Forming Machine
Mold Side of the Forming Machine
Delivery Equipment
Gob enters the delivery
system at 1700 ºF
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
Forming Machine
12 Section Quad
On the Windsor machines,
12 Individual Sections produce 4 bottles at each section
There are 4 cavities in each section. Each cavity has
a 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”.
What is a Parison?
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:
Finish
Hollow inside
Cooler 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
5) Parison
Reheat
3) Press
4) Plunger
Down
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
Start transfer
Parison
Container Formation
Parison transfer to mold
Compressed
Start pickup
air
applied
Mold closes
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
Annealing lehr
Tin spray
coating application
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.
• 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.
Annealing & Surface Treatment
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.
After discharge from the forming machine, the
bottle must be annealed. Annealing is the
controlled removal of heat from the glass container
Surface Treatment
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 bottles
at the lehr discharge.
Surface Treatment
Hot End Application
Tin is vaporized onto the bottles.
Annealing Lehr Cross sectional view
Heating zones
1200
800
ºF
400
0
Cooling zones
Typical annealing temperature curve
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
Owens-Brockway Glass
Glass Containers
Containers Inc.
Inc..
Annealing Lehr Cross sectional view
Heating zones
1200
Cooling zones
Typical annealing temperature curve
Annealing point
800
ºF
400
0
Owens-Illinois
Annealing The Glass Container
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
Lehr Discharge
Polariscope
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.”
Annealing Strain Discs
Surface Treatment
Cold End Application
Polyethylene is sprayed between the rows of bottles.
Backup sprays are also available should the first unit fail to apply
treatment. A diffusion hood is used to keep spray from the bottom
backup unit reaching the finish of the bottle.
Surface Treatment
Spray Head Location
Spray head
must be below finish.
Lehr conveyor mat
Diffusion hood airflow must be sufficient
to keep treatment off of the finish.
Inspection
Automatic 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 sheets
and stretch wrapped with plastic.
QUESTIONS?