GLASS

INDUST
RY
Methods of
Manufacture

WHAT IS A GLASS?
Glass
is
an
inorganic,
homogeneous
and
amorphous
substance obtained through the
cooling of a molten mass. It is the
union of the nonvolatile inorganic
oxides
resulting
from
the
decomposition and fusion of alkali

COMPOSITION OF GLASS

RAW MATERIALS
Sand or Silica (SiO2) is the basic
raw material for manufacturing glass
that has vitrifying functions. Its iron
content should not exceed 0.45% for
tableware, or 0.015% for optical glass,
as iron affects the color of most glass
adversely.

RAW MATERIALS
Soda ash (Na2O) is useful in
oxidizing iron and in accelerating the
melting.
Limestone or Calcium Oxide
(CaO) provides stability to the glass
against
attacks
of
atmospheric
agents.

RAW MATERIALS
Magnesium Oxide (MgO) ensures
the resistance to the glass in order to
support its abrupt changes of
temperature
and
increases
the
mechanical resistance.

RAW MATERIALS
The Alumina (Al2O3) content serves
to lower the melting point of the glass
and to retard devitrification.
Feldspars are usually sources of
alumina. These are composed entirely
of glass-forming oxides.

RAW MATERIALS
Borax does not only lower the
expansion
coefficient
but
also
increases the chemical durability of a
glass.
Salt cake is used to remove the
troublesome foam from tank furnaces.

RAW MATERIALS
Cullet is broken or crushed glass
from waste glass. It saves energy and
raw materials.
Additives such as colorants like
iron and carbon provide color to the
finished glass.

CLASSES OF GLASS
Soda-lime glassis the kind of
glass used for flat glass. The
composition is about 72 % silica,
about 13% sodium oxide, about 11%
calcium oxide, and about 4% minor
ingredients. Soda-lime glass is easy to
melt and shape, and reasonably
strong.

CLASSES OF GLASS
Soda-lead glass (crystal-lead
glass)is made by substituting lead
oxide for calcium oxide and often for
part of the silica used in soda-lime
glass.
It
has
beautiful
optical
properties that it is widely used for
the finest tableware and art objects.

CLASSES OF GLASS
Borosilicate glassis heat-shock
resistant. It contains about 80% silica,
4 % sodium oxide, 2 % alumina, and
13 % boric oxide. Such glass is
excellent for chemical and electrical
uses.

CLASSES OF GLASS
Fused silica glassis a highly heatshock resistant glass that consists
entirely of silica. It can be heated to
extremely high temperatures and
then plunged into ice-cold water
without cracking.

CLASSES OF GLASS
Colored glassgets its coloring
from certain oxides that are added to
the glass. Nickel oxide produces a tint
that may range from yellow to purple.
Cobalt gives an intense blue. Red
glasses are made with gold, copper,
or selenium oxides.

CHEMICAL REACTIONS
Na2CO3 + aSiO2 Na2OaSiO2 + CO2
CaCO3 + bSiO2 CaObSiO2 + CO2
Na2CO3 + cSiO2 + C Na2OcSiO2 +
CO2 + CO

Manufactur
ing Process
of Glass

HOT
END
PROCES
S

PREPARATION OF RAW
MATERIALS
The mixture of raw materials used in
the production of flat glass is known as
the batch which is composed of three
main components: silica sand, soda ash
and dolomite/limestone.

MELTING AND REFINING

Melting is done by batches or as a
continuous process. It takes around 24
hours for the raw materials entering the
furnace to be converted into glass.

BLOWING
In machine blowing, blasts of
compressed air are used to force gobs or
ribbons of glass into molds. Bottles are
made by machine blowing.
In hand blowing, a mass of molten
glass is gathered on the end of a 4 to 5
foot pipe called a blowpipe or blowing

PRESSING
A measured amount of molten glass is
placed, by machine, into a mold, and a
metal plunger presses the glass outward
to fill the mold. When the glass has
cooled and is firm enough to hold its
shape, the mold is removed.

PRESS AND BLOW METHOD

BLOW AND BLOW METHOD

DRAWING
In producing flat drawn glass, a
horizontal wire called bait is lowered into
the molten glass and then raised. Glass
adheres to the wire and is drawn upward
as a continuous sheet. Once hardened,
the glass is cut into sheets.

FLOATING/ FLOAT BATH

Molten glass is allowed to flow onto a
bath of molten tin at 1100C and is then
allowed to cool. The tin has a low
melting point and remains liquid at
temperatures at which the glass
hardens. The surface of the metal leaves
the glass with a very smooth surface.

ROLLING
This method is typically used for flat
glass that does not require a fine finish,
such as glass made with a figured
pattern on its surface.

ANNEALING
In annealing, glass products are
reheated in ovens called lehrs, and then
allowed to cool slowly under controlled
conditions, to ensure the solidity of the
freshly formed glass containers.

TEMPERING
The glass is heated to just below the
temperature at which it would begin to
soften and is then quenched (rapidly
chilled) to stress its entire surface
uniformly. If a piece of tempered glass is
pierced in any way, the uniformity of the
stress is destroyed and the whole piece
shatters into small pieces.

DECORATING
Some glass objects are painted or
glazed.
Others
are
etched
with
hydrofluoric acid, either to produce an
artistic design or to frost the entire
surface.

QUALITY INSPECTION

PACKAGING AND SHIPPING

COLD END
PROCESS

INSPECTION EQUIPMENT
LABELING
This
isscreen-printingof
the
decoration onto the container with
vitreous enamelpaint, which is then
baked on.

COATING
Glass containers receive two surface
coatings, one at thehot end, just before
annealing, and one at thecold end just
after annealing.
At thehot end,a very thin layer oftin (IV)
oxideis applied either using a safe organic
compound or inorganicstannic chloride. At
thecold
end,a
layer
of

COATING
Glass containers receive two surface
coatings, one at thehot end, just before
annealing, and one at thecold end just
after annealing.
At thehot end,a very thin layer oftin (IV)
oxideis applied either using a safe organic
compound or inorganicstannic chloride. At
thecold
end,a
layer
of

COOLING
PACKAGING

Manufactu
re of
Special
Glass

FIBERGLASS
Raw materials :
Silica

sand

Limestone
Soda

ash

Calcined
Borax

alumina

FIBERGLASS
Manufacturing Process:
Melting
Forming

into Fibers

Continuous-filament
Staple-fiber

Process

Process

FORMING INTO FIBER

LAMINATED SAFETY GLASS

It is a type of laminated glass where in
the case of breakage the interlayer serves
to retain the glass fragments, limits the size
of opening, offers residual resistance and
reduces the risk of cutting or piercing
injuries.

LAMINATED SAFETY GLASS

Manufacturing Process:
Feeding
Cleaning
Lamination

COATED GLASS
It is an insulating glass that has been
treated to help retain building heat.Coated
glass also blocks ultraviolet and infrared
light.

COATED GLASS
Manufacturing Process:
Feeding
Cleaning
Vacuum

Coating

FLAT GLASS
Flat
glass,sheet
glass,glass
pane,
orplate glassis a type ofglass, initially
produced in plane form, commonly used
forwindows, glass doors, transparent walls,
andwindshields.

FLAT GLASS
Manufacturing Process:
Melting
Float

& Refining

bath

Coating