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Industrial visit / HNG

SUBMITTED BY : TAMAL MISHRA
PG/K/10/07

Introduction :

 HNG was founded by Mr. C K Somany in 1946 following the

commissioning of India’s first fully automated glass manufacturing
plant at Rishra (near Kolkata). At present, it is the key player in
India’s container glass industry with a pan India presence and its
plants located at Rishra, Bahadurgarh, Rishikesh, Neemrana, Nashik
and Puducherry. HNG has captured a large share of the Indian market
and also has an increasingly satisfied client base in more than 23
countries.

Strategy: We are the largest container glass solutions provider in

India and we look forward to be a global leader in container glass
packaging industry. Our strategy is to create world class products, so
that we can satiate the demands of our consumers and thus, surpass
our contemporaries in competition. It is with our integrated efforts and
customer service that we have managed to keep our growth rate on an
upward swing; in spite of the present economic turmoil, which has
adversely affected people's lives and ways in which business is being
conducted.

Objectives: At HNG, we look forward to customer satisfaction. Our

main objective is to ameliorate our customers and stakeholders, and in
the process strengthen the roots of our organization, so that we can
emerge as a behemoth in the glass packaging industry.

Values: As we climb the success ladder, it is becoming increasingly

important for us to define our core values, as it is our values that help
us remain grounded and focused towards our goals. It gives us a
definite purpose and enables us to make the most of our resources.
 At HNG, we believe in the core values of people, operational
excellence, innovation and integrity.

It is our people that give us the gusto to move forward, keeping all
the obstacles at bay. With our diligent workforce, production has
become so much easy!

Our operational excellence has given us the strength to launch our

products with even more confidence. We have an installed capacity of
2825 TPD and this is what distinguishes us from our competitors.

Innovation and integrity are two important things that drive the
HNG team. \

 These values are like assets that consolidate us in our march towards a
greater future.
 Hindustan National glass & Industries Ltd. Rishra established in 1952

The benefits of light-weight container glass bottles:

- Accelerated bottling process
- Increased bottles per ton
- Reduced price per bottle
- Improved bottle quality
- Enhanced availability
- Reduced transportation cost
- Enhanced bottle transparency
- Increased strength following uniform and optimum wall thickness

Increase of capacity of the plant

Before in 2000 the capacity of the plant was less than 280 TPD(Ton per
day). Capacity increased to 450TPD in 2001 and also another180 TPD
added in 2004 .Thus capacity since Feb 2006 is at 690TPD.Now capacity
from June 2009 is at 800TPD

The shade produces

Cosmetic ------------5%
Green-----------------3%
Amber-----------------15%
Flint-------------------77%

HNG’s valued customer

Domestic :-
Sabmiller, seagram, USL, Dabur , Horlicks , Cipla, Astrazeneca, Ranbaxy ,
Glaxo, etc

Export countries:-
Kenya, Malaysia, Bangladesh, Nepal, Bhutan, SouthAfrica, Indonesia,
WestIndies,Srilanka etc

New Developments
NNPB Technology

NNPB is a revolutionary process that not only controls the distribution of

glass inside the container, but also reduces the weight of glass by 33%
without having any adverse effects on the performance of the glass
containers. HNG is the first to introduce and commercialize this technology
in India. .

HNG introduced the narrow neck press and blow (NNPB) technology in
2007-08, which lead to the reduction in the consumption of molten glass per
bottle without compromising on product strength. Facilitating superior glass
distribution, this technology reinforces the bottle's resistance to pressure on
the filling line. It also leads to a decrease in logistics cost and increase in
consumer acceptability of the bottles
HNG invested a capital of Rs. 100 Cr. to introduce this technology in India.
On one hand, this technology enabled the company to reduce production
costs and wastages; and on the other, it strengthened capacity utilization.
Through NNPB, HNG strives to remain competitive with other packing
alternatives and continue to be the market leader in India.
Narrow Neck Press and Blow Vs Blow and Blow technology:
The parison facilitates precision in control

Enhanced glass distribution throughout the bottle

Lighter in weight, hence a lower consumption of molten glass

Lower cost
Quality Policy
Customer satisfaction has been the key to our sustained market
leadership. It is, therefore, our policy to:

Consistently provide services in time along with the expectations of our

customers at competitive prices paisa.

Actively pursue ever-improving quality through programmes that enable

each employee to do his job right the first time.

We strongly believe in the future of glass.

Raw materials for manufacturing of Glass

Soda-lime-silica glass

Silica sand(Silicon Oxide)--------------(68-73)%

Limestone(Calcium carbonate)------------(10-13)%

Soda ash(Sodium carbonate)---------------(12-15)%

Alumina(Aluminum oxide)----------------(1.5-2)%

Soda lime silica glass produces in HNG are in three types of

manner .They are a)Amber b)Green c)White

Glass container factories

Broadly, modern glass container factories are three-part operations: the
batch house, the hot end, and the cold end. The batch house handles the raw
materials; the hot end handles the manufacture proper — the furnaces,
annealing ovens, and forming machines; and the cold end handles the
product-inspection and -packaging equipment.

Hot end
The following table lists common viscosity fixpoints, applicable to large-
scale glass production and experimental glass melting in the laboratory:[1]

log10(η, log10(η,
Description
Pa·s) P)
1 2 Melting Point (glass melt homogenization and fining)
3 4 Working Point (pressing, blowing, gob forming)
4 5 Flow Point
Littleton Softening Point (Glass deforms visibly under its
6.6 7.6 own weight. Standard procedures ASTM C338, ISO
7884-3)
8-10 9-11 Dilatometric Softing Point, Td, depending on load[2]
Deformation Point (Glass deforms under its own weight
10.5 11.5
on the μm-scale within a few hours.)
11-12.3 12-13.3 Glass Transition Temperature, Tg
Annealing Point (Stress is relieved within several
12 13
minutes.)
13.5 14.5 Strain Point (Stress is relieved within several hours.)

Furnace

Batch feed (doghouse) of a glass furnace

The hot end of a glassworks is where the molten glass is formed into glass
products, beginning when the batch is fed into the furnace at a slow,
controlled rate. The furnaces are natural gas- or fuel oil-fired, and operate at
temperatures up to 1,575°C. [3] The temperature is limited only by the quality
of the furnace’s superstructure material and by the glass composition.

Forming process
Glass container forming
There are, currently, two primary methods of making a glass container: the
blow and blow method used for narrow neck containers only, and the press
and blow method used for jars and increasingly narrow neck containers. In
both cases a stream of molten glass, at its plastic temperature (1050°C-
1200°C), is cut with a shearing blade to form a cylinder of glass, called a
gob. Both processes start with the gob falling, by gravity, and guided,
through troughs and chutes, into the blank moulds, two halves which are
clamped shut and then sealed by the "baffle" from above. In the "blow and
blow" process, the glass is first blown through a valve in the baffle, forcing
it down into the three piece "ring mould", which is held in the "neckring
arm" below the blanks, to form the "finish", or top of the parison. The
"rings" are sealed from below by a short plunger. After the "settleblow"
finishes, the plunger retracts slightly, to allow the skin that's formed to
soften, before counterblow" air blows up through the plunger, to create a
parison, or pre-container. The baffle raises, the blanks open, and the parison
is inverted in an arc to the "mould side" by the "neckring arm", which holds
the "parison" by the "finish". As the "neckring arm" reaches the end of its
arc, two mould halves close around the "parison", the "neckring arm" opens
slightly to release the "finish" then reverts to the blank side. Final blow
applied through the "blowhead" blows the glass out, in to the mould, to
make the final container shape. In the case of press and blow process, the
parison is formed with a long metal plunger, which rises up and presses the
glass out, to fill the ring and blank moulds. The process then continues as
before, with the parison being transferred to the mould, and the glass being
blown out into the mould. The container is then picked up from the mould
by the "take-out" mechanism, and held over the "deadplate", where air
cooling helps cool down the still soft glass, until finally, the bottles are
swept onto a conveyor, ready for annealing.

Forming machines
The forming machines hold and move the parts that form the container.
Generally powered by compressed air, the mechanisms are
timed to coordinate the movement of all these parts so that
containers are made.

The most widely used forming machine arrangement is the individual

section machine (or IS machine). This machine has a bank of 5-20 identical
sections, each of which contains one complete set of mechanisms to make
containers. The sections are in a row, and the gobs feed into each section via
a moving chute, called the gob distributor. Sections make either one, two,
three or four containers simultaneously. (Referred to as single, double, triple
and quad gob). In the case of multiple gobs, the shears cut the gobs
simultaneously, and they fall into the blank moulds in parallel.

Internal treatment
After the forming process, some containers—particularly those intended for
alcoholic spirits—undergo a treatment to improve the chemical resistance of
the inside, called internal treatment or dealkalization. This is usually
accomplished through the injection of a sulfur- or fluorine-containing gas
mixture into bottles at high temperatures. The gas is typically delivered to
the container either in the air used in the forming process (that is, during the
final blow of the container), or through a nozzle directing a stream of the gas
into the mouth of the bottle after forming. The treatment renders the
container more resistant to alkali extraction, which can cause increases in
product pH, and in some cases container degradation.

Annealing
As glass cools it shrinks and solidifies. Uneven cooling causes weak glass
due to stress. Even cooling is achieved by annealing. An
annealing oven (known in the industry as a Lehr) heats the
container to about 580°C then cools it, depending on the glass
thickness, over a 20 – 6000 minute period.

Cold end
The role of the cold end is to inspect the containers for defects, package
the containers for shipment and label the containers.

Inspection equipment
Glass containers are 100% inspected; automatic machines, or sometimes
persons, inspect every container for a variety of faults. Typical faults include
small cracks in the glass called checks and foreign inclusions called stones
which are pieces of the refractory brick lining of the melting furnace that
break off and fall into the pool of molten glass which subsequently are
included in the final product. These are especially important to select out due
to the fact that they can impart a destructive element to the final glass
product. For example, since these materials can withstand large amounts of
themal energy, they can cause the glass product to sustain thermal shock
resulting in explosive destruction when heated. Other defects include
bubbles in the glass called blisters and excessively thin walls. Another
defect common in glass manufacturing is referred to as a tear. In the press
and blow forming, if a plunger and mould are out of alignment, or heated to
an incorrect temperature, the glass will stick to either item and become torn.
In addition to rejecting faulty containers, inspection equipment gathers
statistical information and relays it to the forming machine operators in the
hot end. Computer systems collect fault information and trace it to the
mould that produced the container. This is done by reading the mould
number on the container, which is encoded (as a numeral, or a binary code
of dots) on the container by the mould that made it. Operators carry out a
range of checks manually on samples of containers, usually visual and
dimensional checks.

Secondary processing
Sometimes container factories will offer services such as labelling. Several
labelling technologies are available. Unique to glass is the Applied Ceramic
Labelling process (ACL). This is screen-printing of the decoration onto the
container with a vitreous enamel paint, which is then baked on. An example
of this is the original Coca-Cola bottle. Absolut Vodka Bottles have various
added services such as: Etching ( Absolut Citron/) Coating (Absolut
Raspberry/Ruby Red)and Applied Ceramic Labelling ( Absolut
Blue/Pears/Red/Black)

Packaging
Glass containers are packaged in various ways. Popular in Europe are bulk
pallets with between 1000 and 4000 containers each. This is carried out by
automatic machines (palletisers) which arrange and stack containers
separated by layer sheets. Other possibilities include boxes and even hand
sewn sacks. Once packed the new "stock units" are labelled and warehoused.

Coatings
surface of the glass more adhesive to the cold end coating. At the cold end a
layer of typically, Glass containers typically receive two surface coatings,
one at the hot end, just before annealing and one at the cold end just after
annealing. At the hot end a very thin layer of tin oxide is applied either using
a safe organic compound or inorganic stannic chloride. Tin based systems
are not the only ones used, although the most popular. Titanium
tetrachloride or organo titanates can also be used. In all cases the coating
renders the polyethylene wax, is applied via a water based emulsion. This
makes the glass slippery, protecting it from scratching and stopping
containers from sticking together when they are moved on a conveyor. The
resultant invisible combined coating gives a virtually unscratchable surface
to the glass. Due to reduction of in-service surface damage the coatings often
are described as strengtheners, however a more correct definition might be
strength retaining coatings.

Ancillary processes – compressors & cooling

Forming machines are largely powered by compressed air and a typical glass
works will have several large compressors (totaling 30k-60k cfm) to provide
the needed compressed air. Furnaces, compressors and forming machine
generate quantities of waste heat which is generally cooled by water. Hot
glass which is not used in the forming machine is diverted and this diverted
glass (called cullet) is generally cooled by water, and sometime even
processed and crushed in a water bath arrangement. Often cooling
requirements are shared over banks of cooling towers arranged to allow for
backup during maintenan

For glass chemicals are used given below………

-Sodium sulphate for Amber and White colour glass

-Sellenium powder
-Iron oxide
-Petrolium coke

Chemical used for white & Amber glass

Sio2
Al2o3
Cao
Mgo
K2o
So3

Steps for Glass manufacture in HNG

1)Raw material testing & storage

2) Batch weighing & mixing as per formula
3)Conveying to furnace silos
4)Batch melting operation at furnace
5)Conditioning at distributor and forhearth
6)Formulation at is machine
7)Anneling operation at lehrs
8)Soring
9)Packing
10)Warehousing & Despatch