Completed training at Piramal glass limited, Jambusar from 3rd to 18th June 2015, learned about the manufacturing of glass bottles

1. Report on summer industrial training at
PIRAMAL GLASS LTD. JAMBUSAR
Prepared by
Utkarsh Sethia
Undergraduate student, SRM University, Kattankulathur
(Chennai)
Reg no – 1071310038
Under the guidance of
Mr. Dasgupta sir
Senior Manager – Glass

2. SELF DECLARATION
I UTKARSH SETHIA a student of SRM University Kattankulathur,
Chennai (Reg no – 1071310038) states that I have completed
my industrial training in PIRAMAL GLASS LTD. JAMBUSAR from
3/06/2015 to 18/06/2015.
I affirm that this industrial training report is the record of
authentic work carried out by me and no part or whole of this
report has been submitted to any where for any purpose.
Signature

3. ACKNOWLEDGEMENT
I take this opportunity to thank PIRAMAL GLASS LTD.
JAMBUSAR for giving me the opportunity to do industrial
training here. It gives me immense pleasure to acknowledge all
those who have given me data, time and energy to supply all
the valuable facts and opinions that has helped me in gaining
some technical knowledge in glass industry during this
industrial training.
I express my profound sense of gratitude to M.P. Rajesh sir
(HOD , Chemical engineering , SRM University) ,Y N Jadeja sir
(Sr. Manager – HR , Piramal glass ltd.) and Mr. Dasgupta sir (Sr
Manager – Glass , Piramal glass ltd.) who have rendered
constant guidance, advice and help me when needed to
complete this Industrial training successfully. I also express my
gratitude to the company employees who have helped me
during this time.

4. Table of contents
Serial no. Title Page no.
1 Self Declaration
2 Acknowledgement
3 Introduction and company profile 5
4 Objectives during industrial training 6
5 Safety induction 7
6 Glass container/Glass bottles manufacturing
process
8 - 11
7 Chemical Laboratory 12 - 16
8 Batch house 17 - 18
9 Glass melting Furnace 19 - 21
10 Physical laboratory 22 - 24
11 RO plant (reverse osmosis plant) 25 - 26
12 Bibliography 27
13 Conclusion 28
14 Learning and Observations 29
15 Suggestions 30

5. Introduction
Glass is an amorphous (non-crystalline) solid material which is often
transparent and has widespread practical, technological, and
decorative usage in things like window panes, tableware etc. The most
familiar, and historically the oldest, types of glass are based on the
chemical compound silica (silicon dioxide), the primary constituent
of sand. Soda-lime glass, composed of approximately 75% silicon
dioxide (SiO2), sodium oxide (Na2O) from sodium carbonate
(Na2CO3), calcium oxide, also called lime (CaO), and several minor
additives. A very clear and durable quartz glass can be made from pure
silica; the other compounds above are used to improve the
temperature workability of the product.
Company profile
Piramal Glass Limited (formerly known as Gujarat Glass Pvt Ltd) is an
Indian glass packaging company providing packaging for pharmaceutical
and perfume industry. Prior to acquisition in 1984 by Piramal Group,
the company located its manufacturing plant in Kosamba, Gujarat. In
1990 Gujarat Glass Pvt Ltd merged with its parent company Nicholas
Piramal India Ltd to become one of its many divisions.
Piramal glass manufactures glass containers and glass bottles. At
jambusar plant flint glass and amber glass bottles are manufactured.
Jambusar plant has three furnaces 125 tpd, 160 tpd and 255 tpd
furnace. 255 tpd furnace produces amber type III Soda lime container
glass. 160 tpd and 125 tpd furnace produces Flint type III Soda lime
container glass.

6. Objectives during Industrial training
1) To learn about how the raw materials used in glass
manufacturing processes are stored and handled.
2) To learn about various manufacturing processes involved
in making glass bottles from raw materials.
3) To observe and work in the industry as guided by the
mentor.
4) To learn about how the quality of a glass bottle is
maintained.
5) To gain practical knowledge in the field of glass industry.
6) To know about the working of a glass industry through
interaction with company employees.

7. Safety induction
Safety, health and environment (SHE) cell guided me regarding the safety
measures / equipments in the industry. Some of these are:-
 Safety shoes – these are meant to provide protection to the feet under
extreme conditions such as to avoid shocks, abrasion resistance, oil
resistance, heat resistance and others.
 Safety goggle – It is meant for protecting eye from chemicals, dust and from
the radiations coming from high temperature sources.
 Ear plug - An earplug is a device that is meant to be inserted in the ear
canal to protect the user's ears from loud noises or the intrusion of water,
foreign bodies, dust or excessive wind.
 Dust mask - It is a flexible pad held over the nose and mouth by elastic or
rubber straps to protect against dusts encountered during the handling of
raw material in batch house.
 safety helmet – It is a type of helmet predominantly used in workplace
environments such as industrial or construction sites to protect the head
from injury due to falling objects, impact with other objects, debris, rain,
and electric shock.

8. Glass container/Glass bottles manufacturing
process
The glass bottles manufacturing process is a three-part operation process:
the batch house, the hot end, and the cold end. The batch house handles the raw
materials; the hot end handles the manufacture process — the furnaces,
annealing ovens, and forming machines; and the cold end handle the product-
inspection and -packaging equipment.
a) Batch house
The batch house simply houses the raw materials in large silos (fed by
trucks). The batch house measures, assembles, mixes, and delivers the glass
raw material recipe (batch) via an array of chutes, conveyors, and scales to

9. the furnace. The batch enters the furnace at the 'dog house' or 'batch
charger'
b) Hot end
 Furnace - The batch is fed into the furnace at a slow, controlled rate
by the batch processing system (batch house). The furnaces
are natural gas- or fuel oil-fired, and operate at temperatures up to
1,575 °C.
 Forming process - A stream of molten glass, at its plastic temperature
(1,050–1,200 °C), is cut with a shearing blade to form a solid cylinder
of glass called a gob. The gob is of predetermined weight just
sufficient to make a bottle. The gob falls by gravity and is guided
through troughs and chutes, into the blank moulds. Now compressed
air is blown through the glass, which gives the glass bottle a final
shape.
 Internal treatment – It is a treatment to improve the chemical
resistance of the inside of the bottle. The process is also called
dealkalization. This is usually accomplished through the injection of a
sulfur- or fluorine-containing gas mixture into bottles at high

10. temperatures. Currently in Piramal glass Ltd. this process is under
study.
 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 (1,076 °F), then cools it,
depending on the glass thickness, over a 20 – 6000 minute period.
c) Cold end
The role of the cold end is to spray on a polyethylene coating for abrasion
resistance and increased lubricity, inspect the containers for
defects, package the containers for shipment, and label the containers.
Steps involved in manufacturing of bottles:-
a) Different types of raw materials are carried by trucks - (Dolomite, Calcite
powder, Silica sand – A , Silica sand – B , Silica sand – E, Limestone , Coke
powder, Soda ash (dense), Feldspar, Red oxide)
b) Different types of raw materials are stored in different bins.
c) Different types of raw materials are moved to different silos through
conveyor belts.
d) Different types of raw materials are individually weighed (as per required
quantity) with the help of weighing scales.
e) The mixer mixes all these raw materials along with cullet in required
proportion to prepare batch.
f) The batch thus prepared is moved to dog house, from where it is fed into
melter.
g) In melter this mixture of raw materials react to give melted glass
h) Now melted glass flows through:-
 Throat (it connects melter to the distributor)

11.  Distributor (it acts as a melted glass distributing system. It has
various zones at different temperatures)
 Forehearth (here, glass conditioning takes place. In a particular
forehearth , glass is maintained at a particular temperature as per
glass bottles requirement)
i) At the plastic temperature of glass, a gob is formed.
j) With the help of moulds, glass is given a particular shape to form glass
bottles.
k) In LEHR , annealing process takes place . In this process stress is removed
from the bottles.
l) Glass bottles are inspected for any defect by quality control department.
m) Glass bottles are packed for marketing.

12. Chemical Laboratory (Quality analysis lab)
Following are the equipments in chemical lab for testing the quality of
glass and the raw material from which it is made:-
a) X-ray fluorescence (XRF) spectrometer - An x-ray instrument used for
routine, relatively non-destructive chemical analyses of rocks, minerals,
sediments and fluids. In glass industry it is used for elemental and chemical
analysis in the investigation of glass.
b) Fume hood - It is a type of local ventilation device that is designed to limit
exposure to hazardous or toxic fumes, vapors or dusts.
c) Density comparator - For determining the density of glass.

13. d) Fractionating column - for obtaining very pure distilled water by the
process of fractional distillation.
e) Hydride generation atomic absorption spectrometer (HGAAS) - Metalloids
like antimony, arsenic, selenium, and tellurium are analyzed by HGAAS.
f) Flame photometer – This instrument is used for analyzing and measuring
the content and concentration of elements (K , Na , Li , Ca , Ba) in glass and
raw materials.
g) Muffle furnace - A box-type oven for high temperature applications such as
fusing glass.
h) Hydraulic press - A device using a hydraulic cylinder to generate a
compressive force. In glass industry it is used to make small disc shaped
sample of sand, limestone, soda ash etc. The sample thus formed is further
analyzed for its chemical composition.
i) Autoclave - It is a pressure chamber used to sterilize equipment and
supplies by subjecting them to high pressure saturated steam at 121 °C for
around 15–20 minutes depending on the size of the load and the contents.
j) Electromagnetic sieve shaker – An equipment used in sieve analysis (for
determining the particle size distribution of a granular material).
k) Moisture analyzer - for measuring moisture content in both high level and
trace amounts in solids (sand, limestone, feldspar etc).It displays
temperature, time, moisture%
l) Weight balance – For weighing purpose
m) Electric oven – It is used to heat the sample and thus remove moisture from
it so that it can be analyzed further.
n) Glass cutting machine – It is used for cutting glass to form small disc shaped
sample of glass. The sample we get after cutting process has rough surface.

14. o) Twin variable speed grinder polisher – It is used to polish the sample of
glass. Polishing paper discs, cerium oxide powder and water are used in the
process of polishing.
p) Mini ball mill – It is used to reduce the particle size of sample by using
impact energy. The energy from the impact of the moving balls beaks down
the sample until the final required fineness is achieved.
q) Silica gel – It is used to control moisture in the sample.
r) Binding agent – PVA solution (it is used while preparing test sample of sand
, feldspar etc)
s) Acetone - It is used along with binding agent to make test samples. It acts as a
drying agent.
t) UV/Vis Spectrometer – It uses the principle of Beer-Lambert law to find
transmittance and absorbance of a glass sample.
Sample reading for UV/Vis spectrometer - Lambda 35 (taken with
permission)

15. Data for JBR AMBER_04 06 15-01 . Sample (A). (For a particular known
thickness of glass)
S.no. Wavelength of radiation (slit width – 1 nm) Absorbance
1 290 nm 3.497
2 310 nm 3.383
3 330 nm 2.421
4 350 nm 2.423
5 370 nm 2.355
6 390 nm 2.191
7 410 nm 2.137
8 430 nm 2.077
9 450 nm 1.803
10 550 nm 0.681
11 650 nm 0.469
12 1050 nm 0.680
Similar data is recorded for different thickness of glass and following result is
obtained.
Result (Transmission report)
 Transmission at 550 nm  32.91%
 FeO  0.244
 Redness factor  1.5374
 450 nm  3.86
Types of samples tested in Quality analysis laboratory:-
 Dolomite
 Calcite powder
 Silica sand – A
 Silica sand – B
 Silica sand – E
 Limestone
 Coke powder

16.  Soda ash (dense)
 Feldspar
 Red oxide
Safety in quality analysis lab:-
 Emergency shower (safety body shower and safety eye shower)
 Fire extinguishers (Carbon dioxide based and Dry powder based)
 Emergency exit
Some reasons for rejection of raw material (ex – sand, feldspar, soda
ash etc):-
 High fines ( ex – 100 BSS < 15% for dolomite )
 Low SiO2 %
 Low CaO %
 High MgO %
 High Fe2O3 %
 High amount of coarse size particles

17. Batch house
Batch house is one of the most essential parts of a glass manufacturing
site. A batch house normally needs to supply several different recipes of
raw material batches to multiple furnaces.
The batch process of the glass facility is divided into four sections.
a) Silo feeding
It consists of feeding the raw material into one of the multiple silos or
hoppers. When unloaded from the trucks raw material is conveyed through
a series of bucket elevators and conveyor belts to the silica, soda ash,
limestone, feldspar or sodium sulphate silo. Each of these silos are fitted
with level transmitters, pressure switches and over pressure flaps that are
all controlled by the batch control room . The silos have a series of de
dusting units that help in trapping the excess dust, which tends to rise as
the silos get filled up. These de dusting units comprise of dust collectors
and blower fans. At every stage magnetic separators will prevent iron
impurities finding their way into silos.

18. b) Batch weighing and transport
This section deals with the weighing, dosing and transport issues of the
batch plant. Dosing into the weigh scales is either through screw feeders,
pneumatic feeders or vibrating feeders. The time and sequenced dosing of
the raw material is completely controlled by batch control room. The
conveyors are again controlled by batch control room.
c) Mixers
Normally a plant is equipped with several mixers each driven by a motor.
Raw material is fed to the mixer that has to be filled through a swivel pipe.
Batch control room ensures that the mix reaches the desired consistency
before it is fed on to the main conveyor belt.
Cullet is added to the mix on the conveyor belt to get the final mixture that
is ready to be loaded in the furnace .Single or multiple batch chargers takes
the final mix from the furnace silos from where it is fed into the melting
furnace.
d) Cullet and cullet return
Glass production companies use cullet from external suppliers as well as
the cullet that is returned from their own production line. Conveyor belts
are used to transport the cullet into the batching process. Incoming cullet
from external sources is loaded into a hopper that feeds the cullet to a
series of crushers. On its way to the cullet silo the cullet passes magnetic
detectors and magnetic separators that keep iron parts away from the silo
and finally from the raw glass melt.

19. Glass melting Furnace
With the viewpoint of Piramal glass ltd., glass melting furnace is explained as
follows:-
Type of furnaces in piramal glass ltd. – Regenerative end port (a type of tank
furnace)
Tank furnace:-
Tank Furnaces are used where continuous flow of glass is needed to feed automatic
glass forming machines. They are more economical (as compared to pot furnaces) in
their use of fuel and are used for the large scale production of containers (glass bottles).
A tank furnace consists of a bath, built of a very special high refractory material, which
can resist chemical attack of molten glass at temperatures in excess of 1500°C and a
superstructure where combustion takes place.
In order to achieve high melting temperatures and fuel economy, a regenerative system
is used. This system utilizes the waste heat of combustion for pre-heating the incoming
combustion air.
Regenerative furnace (a type of tank furnace):-
In a regenerative furnace, air for combustion is preheated by being passed over hot
regenerator bricks, typically called checkers. This heated air then enters an inlet port to
the furnace. By using one or more burners, fuel is injected at the port opening, mixes
with the air, and burns over the surface of the glass. Products of combustion exhaust
out of the furnace through a non firing port and pass through a second set of checkers,
thereby heating them. After a period of 15 to 30 min (20 minutes for 105 TPD and 160
TPD furnace and 30 minutes for 255 TPD furnace in piramal glass ltd.) , a reversing
valve changes the flow and the combustion air is passed over the hot checkers that
were previously on the exhaust side of the process. The fuel injection system also
reverses. After reversing, the exhaust gases pass through and heat the checkers that
had previously heated the combustion air.
Type of fuel used:-

20. Heavy fuel oil or natural gas is normally used for firing tank furnaces. Glass, being an
electrical conductor at high temperature, can also be melted by electricity. However,
electricity is far too expensive and is normally used to boost the output from a gas or oil
fired furnace.
End-Port regenerative furnace:-
In an end-port furnace, the ports are located on the furnace back wall. Batch is charged
into the furnace near the back wall on one or both of the side walls. The following figure
shows the layout of a typical end port furnace.

21. The above figure shows the inside view of a melter

22. Physical laboratory (Quality control laboratory)
Quality control (QC) is a procedure or set of procedures intended to ensure that a
manufactured glass product adheres to a defined set of quality criteria or meets
the requirements of the client or customer.
Following are the equipments/tests that are used in quality control
laboratory:-
a) Polariscope – It is used to help detect the presence of glass strain. By
looking through two polarized filters held in varying orientation one can
visualize the stress patterns in a piece of glass.
b) Inspection of cold end coating - Glass containers receive surface coating at
the cold end just after annealing. At the cold end a layer
of polyethylene wax is applied on the surface of glass bottles. This makes
the glass slippery, protecting it from scratching and stopping containers
from sticking together when they are moved on a conveyor.
c) Thickness tester – This device measures the thickness of glass bottles

23. d) Shaker testing - A shaker is a device used in vibration testing/shaker testing
to excite the structure for endurance testing. This test is mainly used for
testing nail polish bottles
e) Drop test – This test is performed to ensure that containers have sufficient
resistance to withstand impact during Transportation and Packaging.
f) Vertical load testing machine – This test is used to determine product’s
resistance to vertical load forces.
g) Profile projector - The projector magnifies the profile of the glass bottle,
and shows this on the projection screen. It is utilized for measuring
dimensions and for designing purpose.
h) Weight and capacity measurement device
i) Digital vernier caliper
j) Leakage test or vacuum test - Leak Test Machines have the ability of testing
minutest leakages with utmost accuracy with pressure drop & vacuum
method.
k) Thermal shock testing machine – It is used to test containers strength to
withstand stresses due to high temperature gradient. This test is performed

24. on glass containers that may be subjected to high differences in
temperature during their normal use.
l) Bursting test – This test is performed to Ensure that bottles are able to
withstand internal pressure due to evaporation at high temperatures
m) Inspection of hot end coating - Glass containers receive surface coating at
the hot end, just before annealing. In lab this coating is analyzed.
n) Impact tester – This test is performed to ensure that the glass bottles can
withstand impact force in day to day use.

25. RO plant (reverse osmosis plant)
Following are the steps involved in an RO plant process at piramal glass ltd.
a) Feed tank – Water after being treated in effluent treatment plant (sewage
treatment plant) comes here and is stored in the tank.
b) Feed pump
c) Acid dosing system – Hydrochloric acid (HCl-33%) is added into the feed
water just before filtration to maintain a pH level of about 6.5 to allow any
un-precipitated materials to be filtered.
d) Filter pump
e) Sand filter – It removes the particles of size greater than 15 microns from
feed water. It also removes turbidity from water.
f) Anti scaling dosing system – The purpose of this system is to reduce the
potential of calcium carbonate scaling in the RO system. Certain acidic
chemicals (HCl, H2SO4) are added to feed water to prevent the formation of
scales.
g) Cartridge filter –It removes the particles of size greater than 10 microns
from feed water.
h) High pressure (H.P.) pump -1,2,3 and 4  All of them are used to pump
water in membrane module 1
i) Pulsation dampers - pumps produce pulsating flows which lead to pressure
spikes. These pressure spikes may not be desirable in a given piping system
, therefore there is a need for a pulsation dampener.
j) Membrane modules (stage 1)  It has 37 modules (1 module has 183
membranes and 185 hydraulic discs)
k) Booster pump 1
l) Membrane modules (stage 2)  It has 28 modules
m) Booster pump 2
n) Membrane modules (stage 3)  It has 28 modules
o) Booster pump 3
p) Membrane modules (stage 4)  It has 27 modules

26. q) Now two types of streams are formed:-
 Reject (this water is send to MEE (multiple effect evaporator) plant
for further processing.
 Permeate – This is the stream of water that has passed the
membranes.
r) Intermediate permeate tank
s) Intermediate permeate transfer pump
t) Degasser blower motor – Impurities are removed further in this process
u) Final permeate tank and pump
v) Final storage tank – used everywhere in the plant except for drinking and
food making purpose.
Note:-
Particles of size greater than 1 angstrom cannot pass membrane modules.

27. Bibliography
 Information from various department
heads and employees in the company
 Information from the specification boards
in the company
 Wikipedia -
https://en.wikipedia.org/wiki/Glass_prod
uction
 Information obtained from various
websites –
http://www.eurotherm.com/industries/gl
ass/glass-applications/batch-house-
control/
 Various research papers available on
internet
 Information obtained from learning
centre in the company.

28. Conclusion
I conclude that while going through the entire industrial training, the cooperation
is found to be very well organized and developed in every walk of its production,
administration & management aspects.
During this industrial training I have gained a lot of practical knowledge in the
field of glass bottle manufacturing, RO plant working, effluent treatment plant
working etc.
I extend my heartiest thanks to PIRAMAL GLASS LTD. JAMBUSAR for making my
industrial training a memorable period in my life. Interaction with company
employees has also helped me in learning about various processes and machines
used in the industry. I feel myself lucky to get an opportunity to do industrial
training in such an esteemed company.
At last I want to say THANK YOU

29. Learning and Observations
 I have learned a lot about how a glass industry works.
 Through interaction with company employees, I came to
know about new things and what is the future in/of glass
industry.
 I have learned new ways to treat the fellow members which is
a very important thing in any industry.
 Everyone here in the company is very cooperative and this
helped me a lot during this industrial training.
 Safety is promoted, followed and maintained in every
department of the company, this helps in preventing any
industrial accident/disaster.
 There is a team spirit in every department of the industry.
 There is cooperation among the departments which is a key
factor in the growth of any industry.
 Food quality is good.
 The company has a friendly environment for students doing
industrial training here.
 Besides glass making process I have also learned about how
waste water is treated in an industry and how a reverse
osmosis plant works.
 The quality of raw material used for making glass is
maintained and also the quality of glass bottles formed is
checked.
 The buses from vadodara to piramal glass limited are always
on time and are comfortable.

30. Suggestions
My suggestions regarding the improvement of this industry are as follows:-
 The ambient air temperature in 160 TPD plant is much less than 255 TPD
and 105 TPD plant. Something must be done (ex – use and maintenance of
appropriate insulating materials) to reduce the heat loss from the furnaces
(especially 255 TPD and 105 TPD plant). Also 255 TPD plant and 105 TPD
plant are too much compact as compare to 160 TPD plant and this may be
the reason for their higher ambient air temperature.
 A research and development (R and D) lab must be set up in PIRAMAL
GLASS LTD. JAMBUSAR which will work for the development and
improvement of processes in all the departments.
 Company must derive a part of its energy and electricity needs from
renewable sources ( ex solar , wind etc)
 The use of proper safety equipments must be encouraged in cullet
processing plant. There is one place in cullet processing plant where fine
dust of glass flows / is suspended in air (if a person is there for around 15
minutes then itching starts). So, my suggestion is to cover the whole cullet
processing plant inside closed walls.
My suggestions regarding the improvement of industrial training process in
PIRAMAL GLASS LTD. JAMBUSAR are as follows:-
 Online forms for doing industrial training in piramal glass ltd. must be
available on internet (on websites like internshala).
 In spiral type RO plant usually there is no one to guide the trainees while
in disc type RO plant and MEE plant the employees are very cooperative,
so company must look into this aspect.
 In batch control room also usually the employees are very busy, so there
must be someone for guidance.