Glass Packaging

By
Shailesh Jadhav
 Contents
APPLICATION
ADVANTAGES
BASICS
MANUFACTURE
DESIGN FEATURES
TYPES & PROPERTIES
PERFORMANCE & TESTING
 APPLICATION
Pharmaceutical
Cosmetics
Food
Beverages
 ADVANTAGES
Chemically Inertness
Oxygen, Moisture barrier resistance
Better visibility of contents
Better strength in compression
Easy Cleaning, sterilizing, reusability and
recycling
Heat resistance
Impervious to odour and Vapour
 LIMITATIONS

High tare weight

Fragile and Breakage due to shock and impact
Thermal effect creating crack
Scuffing and Surface abrasion
Labels need to applied
It is not for load supporting
 What is a Glass

SUPERCOOLED LIQUID
LIQUID WHICH IS COOLED TO A STAGE WHERE
ITS VISCOSITY IS SO GREAT THAT THE
MOLECULES DO NOT MOVE FREELY ENOUGH
TO FORM CRYSTALS
 What is glass made of ?

Sand 70%
Soda Ash 15%
Limestone 10%
 Other Material Added
Silica and Sodium Compound-Sodium
silicate-Water glass
Calcium Carbonate-Substance insoluble
Aluminium oxide(Alumina)-Improves
durability
Titanium, Al or Zirconium-Increase
surface strength make thinner and
lighter containers
 Other Material Added
Boron compound(Borax and Boric acid)-Low
thermal expansion and high heat shock
resistance
Other additive-reduce the time and
temperature reqd. for melting and presence
of glass bubbles.
Nickel, Cobalt or Selenium-De-colouriser-to
mask colour produce by impurities such as
iron
Lead compound-Clarity in glass
 Colour of Glass
Fluorides White Opal
Cobalt Oxide Blue
Selenium, Cadmium and Antimony
Sulphide-Red
Chromium compound-Green
Iron, Sulphur, and Carbon-Amber or
Brown
 Types of Glass
The European Pharmacopoeia (EP) , USP has stipulated three types of
specialist glass for pharmaceutical applications with specific limits to
the level of titratable alkalis:

T ype 1: a borosilicate glass which meets the most stringent extractable

standard. A disadvantage is the higher melting point of this glass type,
requiring a furnace temperature of 1750C, which increases the cost
of the glass.

T ype 2: a soda lime glass formula that has been sulphated at 500C in
the annealing oven (lehr) to reduce alkali solubility at the glass
surface. The treatment produces a discoloured, hazy appearance.

T ype 3: a conventional soda glass that has been tested and shown to
meet a specified extractives level. In North America, soda glasses not
meeting type 3 qualifications are classed as USP type.
TYPE I BOROSILICATE (neutral) GLASS

ADDITION OF 6% BORON REDUCES LEACHING ACTION

Least reactive glass available for containers.

It can be used for all applications and is most
commonly used to packaged water for injection,
UN-buffered products, chemicals, sensitive lab
samples, and samples requiring sterilization.
All lab glass apparatus is generally Type I
borosilicate glass.
Type I glass is used to package products which are
alkaline or will become alkaline prior to their
expiration date
TYPE II DE ALKALIZED SODA LIME
GLASS

Has higher levels of sodium hydroxide and

calcium oxide.
It is less resistant to leaching than Type I but
more resistant than Type III.
GOOD ALKALI RESISTANCE
It can be used for products that remain below
pH 7 for their shelf life
TYPE III SODA LIME GLASS

Acceptable in packaging some dry powders

which are subsequently dissolved to make
solutions or buffers.
It is also suitable for packaging liquid
formulations that prove to be insensitive to
alkali.
Type III glass should not be used for products
that are to be autoclaved, but can be used in
dry heat sterilization
 GLASS MELTING
Cullet + SAND + OTHER RM MELTED in furnace (15000C)
 GOB FORMATION
Gobs ---to form blank mold
Furnace draw-off orifice and gob shears
Orifice 12 mm to 50mm
Gob is one individual mass of molten
glass which makes one container
Molten glass flows depending on the
bottle size.
Mechanical shears snip off "gobs" of
molten glass. Each makes one container.
Falling gob is caught by spout and
directed to blank molds.
Mass-production is made up of several
individual sections, each is an
independent unit holding a set of bottle-
making molds.
Large bottles consists of a blank mold
and a blow mold.
Higher production using double or triple
gobs on one machine. two or three
blank molds and similar blow molds.
 GLASS MOULDING

TWO TYPES OF PROCESSES

BLOW & BLOW PRESS & BLOW

BLOW & BLOW
 PRESS &
Press-and-Blow process
BLOW
for wide-mouthed jars
Press and blow forms
the parison by mechanical action
Gob delivery and settle-
blow steps are similar to
blow-and-blow forming.
Parison is pressed into shape
with a metal plunger rather
than blown into shape
The final blowing step is
identical to the blow-and-
blow process.
Used for smaller necked
containers.
Better control of glass
distribution
 DIFFERENCE IN PROCESSES
Difference of the two processes
Blow-and-blow used for narrow-necked bottles.
Press-and-blow used to make wide-mouthed jars and for
increasingly smaller necked containers. Better control of
glass distribution.

Typical production rates range from 60 to 300 bottles per

minute, depending on the number of sections in a
machine, the number of gobs being extruded, and the
size of the container.

The blown bottle is removed from the blow mold with

takeout tongs and placed on a dead plate to air cool for
a few moments before transfer to a conveyor that
transports it to the annealing oven.
 ANNEALING

to reduce internal stresses;

- Walls are comparatively thick and cooling will not be even.
- The inner and outer skins of a glass become rigid
- The still-contracting inner portion build up internal stresses
- Uneven cooling develop substantial stresses in the glass.
- Bottle passes through an lehr after removal from the blow mold.
-

LEHR is a belt passing through the controlled temperature oven at a rate

of about 200mm to 300mm per minute. Glass temp is raised to 5650 C and then
gradually cooled to room temperature with all internal stresses reduced to safe
levels in about an hour as they exit

Improperly annealed bottles are fragile and high breakage

Hot-filling also produce unacceptable breakage levels.
 SURFACE COATINGS
Purpose : to reduce the coefficient of friction

Reasons: The inner and outer surfaces have different characteristics

The outer surface comes in contact with the mold and takes
the grain of the mold surface
Both surfaces are PRISTINE, MONOLITHIC, STERILE,
CHEMICALLY INERT.
Pristine glass has high COF, surface scratching and brushing
can occur when surface rubs on high speed filling lines.
Scratched glass has a breakage resistance

Methods--- hot-end coating ; cold-end coatings

The hot-end coating applied at the entrance to the annealing lehr
to strength the glass surface
Cold-end coatings depending on the filling process and end use.
Typical cold-end coatings---oleic acid, monostearates, waxes,
silicones, polyethylenes
The label adhesive as one cold-end coating.
 INSPECTION & PACKING

Use mechanical and electronic means.

1) Squeeze testers-Force subject the container wall
2) Bore gauger - check height, perpendicularity, inside
and outside finish diameters.
3) Optical devices inspect for stones, blisters, checks,
bird swings, and other blemishes and irregularities by
rotating the container past a bank of photocells.

Faulty containers crushing into cullet.

Transported in reusable corrugated shippers; Shipped on

pallets

Automatic equipment used to clear tiers off the pallet

and feed into the filling machine.
 BOTTLE PARTS

Finish is that part which

receives the closure

Smooth round shapes---easily

formed
Suitable on filling lines
Labeled at relatively high
speeds
Accurately positioned in spot-
labeler
Greater strength-to-weight
ratios
Better material utilization
CSP TRG AIDS - AUG 2008 24
 NECK & SHOULDER AREAS

The impact on filling, air displacement, and dispensing.

Fill level in long narrow necks
Headspace for thermal expansion and facilitate filling.

Manufacturing defect ---choke neck

Ridge on the sealing surface---over press

Upper shoulder --- below the neck.

Shoulder and neck blending ---important design and

production. lower shoulder--- the integration point
between the upper shoulder and the body.
Contact area
 SIDES
The most generalized areas of the bottle.

Labeling styles and preventing scuffing must be

considered. Bottles designed with label panels to prevent
scuffing.

The panel may have prominent base and shoulder ridges.

In angular bottles, rounded corners are preferable for

wraparound or three-side labeling.

Spot labeling is normally a one- or two-sided application.

Labeling of non-round shapes is slower than for round

shapes.
 HEEL & BASE
High-abuse area--- start high from the base curving into the base to a
suitable base diameter.
Body-to-base curve should combine 3 radii.
The largest blends body to heel, the smallest blends heel to base.
Diameter as large as possible as a good design.
Center of the base ensure a flat, stable bottom .
Stippled or knurled on the circular bearing surface to protect the
scratches not to weaken the body during handling and usage.
Ketchup bottles and other sauce bottles require:
heel and base be heavier and contoured when expelling the contents.
Wide-mouthed jar bases have designed-in stacking features.
Container base fits into recessed cap.
Indented container base fits over cap.
Heel tap --- excess glass distributed to the heel.
Closure For Glass Containers
Factor considered in selecting a Closure:
Seal effectiveness
Easy opening and Closing
Recloure
Dispensing
Effect on Decorations
Packaging line problems
Product Compatibility
Cost
Closure For Glass Containers
Types of Closure:
Screw Closure
Lug Closure
Friction Fit Caps
Roll on Caps
Pilfer proof Caps
Crown Caps
 DECORATIO
Frosting - N
Etching by Hydrofluoric Acid (HF) /
Sand blasting Expensive

Ceramic Frosting -
spray with ceramic paint ( ground glass + oil mixture) fire oil
evaporates and ground glass fuses on surface.

Labelling-
Wet glue labelling-Front/Back/Neck Label

Printing-
Screen Printing inks are fired
Metallic Silver and gold effect can be achieved

CERAMIC Decal