Manufacturing of Glass Bottle

1. Manufacturing of Glass
Bottle (Coke)
Mr.Velmurugan.S
AP/AERO/KIT

2. GLASS, CERAMICS AND RELATED
MATERIALS
 glass
 synthetic vitreous fibres
 pottery
 ceramic tile
 industrial ceramics
 brick and tile
 refractories
 synthetic gems
 optical fibres.

3. Common Processes and Hazards
 Batch raw material processes
 Firing or melting processes
 Material handling in production, fabrication,
packaging and warehousing
 Rebuilds and reconstruction activities

4. Definition
 an inorganic product of fusion that has cooled
to a rigid condition without crystallizing
 When glass is cooled from the hot molten state,
it gradually increases in viscosity without
crystallization over a wide temperature range,
until it assumes its characteristic hard, brittle
form. Cooling is controlled to prevent
crystallization, or high strain.

5.  Glass, chemically, is actually more like a liquid,
but at room temperature it is so viscous or
'sticky' it looks and feels like a solid. At higher
temperatures glass gradually becomes softer and
more like a liquid. It is this latter property which
allows glass to be poured, blown, pressed and
moulded into such a variety of shapes.

6. History
 Glass technology has evolved for 6,000 years
 A most important development in glass technology was
the use of a blow pipe
 The first glass was coloured because of the presence of
various impurities such as oxides of iron and
chromium. Virtually colourless glass was first made
some 1,500 years ago.
 Today many products of glass are made in fully
automatic processing lines
 Although glass is one of the oldest materials, its
properties are unique and not yet fully understood.

7. Applications
 Chemistry
 Pharmacy
 Electrical and electronics industries
 Optics industries
 Construction and lighting industries

8. Major constituents
 Silica sand
 Soda ash
 Lime stone
 Dolomite
 Feldspathic materials
 Lead oxide
 Boric acid
 Crushed glass

9. Minor constituents
 The remainder of the batch consists of several
additional ingredients, chosen from a group of
some 15 to 20 materials commonly referred to
as minor ingredients.
 These latter additions are added with a view to
providing some specific function or quality, such
as colour, which is to be realized during the glass
preparation process.

10. Common glasses
 Soda-lime-silica glass (commercial glass)
 Lead-potash-silica glass
 Borosilicate glass

11. Soda-lime-silica glass
 SiO2 (silica) 70%
Na2O (sodium oxide)12%
CaO (calcium oxide) 8%
MgO (magnesium oxide) 3%
Al2O3 (aluminium oxide) 1%
 Commercial glass is colourless
 Additional chemicals have to be added to
produce different colours of glass such as
green, blue or brown glass.

12. Lead-potash-silica glass
 It is made by using lead oxide instead
of calcium oxide, and potassium oxide
instead of all or most of the sodium
oxide
 High refractive index
 Relatively soft surface
 High electrical resistivity
 Radiation protection (higher lead oxide
contents typically 65%absorb gamma rays
and other forms of harmful radiation)

13. Borosilicate glass
 silica (70-80%) and boric
oxide (7-13%) with
smaller amounts of the
alkalis (sodium and
potassium oxides) and
aluminium oxide.
 ovenware and other
heat-resisting ware
(Pyrex)

14. Types of special glass include :
 Vitreous silica
 Aluminosilicate glass
 Alkali-barium silicate glass
 Technical glass
 Glass ceramics
 Opical glass
 Sealing glass

15. Glass making
 Pot process
 Tank process

16. Pot Process
 The manufactured of high quality glass such as
optical and mirror glass & small quantities of
specialty glass
 Hazard of hand shoveling & filling of the pots
 Optical and specialty glasses contain heavy metals
(lead, barium and manganese)

17. Pot Furnace

18. Tank Process
 Permits enclosed &continuous feeding of bath
ingredient (reduced dust exposure)
 Refractory blocks and bricks used in the
construction of the furnaces and tanks contain
free silica.

19. Tank Furnace

21. Glass objects formed by:
 Blowing
 Pressing
 Casting
 Rolling
 Drawing
 Floating

22. The blow pipe

23. Pressing & Blowing

24. Continuous float process

25. Ribbon of float glass exiting from lehr after
being annealed

26. Glass additive
 Accelerate melting
 Stabilizer
 Improved optical properties
 Remove bubbles
 Color

27. Accelerate melting
 Fluorine
 Calcium fluoride
 Sodium silicafluoride

28. Stabilizers
 Increased resistance
 Barium , Lead , Ca , Mg ,Zn oxides

29. Improved optical properties
 Rare earth metals
 Thorium

30. Remove bubbles
 Salts of arsenic
antimony

31. Color
 Salts of chromium ( green –yellow)
cobalt (red – blue )
cadmium (yellow)
manganese
nickel (black)
selenium ( red)

32. Potential health and safety
hazards found during
manufacturing of glass,
ceramic and related
materials

33. Ergonomic stressors; biomechanical
hazards
Uses or sources of
exposure
to hazard
Potential effects (physical
hazards
or health effects)
Precautions or control
strategies
Overexertion from
manual material-
handling practices ,
poor posture, high
frequency/duration of
tasks involving lifting,
pushing or pulling
Strains and sprains in
skeletal muscular
damage to back, upper
and lower extremities
Excessive physical and
mental fatigue can
cause errors leading to
secondary incidents
· Physical demands
assessments of suspect
job tasks
· Use of material-
handling devices
including lift assists,
powered vehicles
· Process automation or
semi automation
· Education on proper
techniques

34. Vacuum lift assist being used to handle 20
to 30 kg packages of textile glass.

35. Physical hazards
Uses or sources of
exposure
to hazard
Potential effects
(physical hazards
or health effects)
Precautions or control
strategies
Caught in or struck
by or against fixed or
mobile equipment
Slips, trips and falls
on walking and
working surfaces,
hoses and other
equipment, tools or
materials
Abrasions, cuts,
contusions,
lacerations,
punctures, fractures,
amputations
· Safe work procedures
· Good housekeeping
practice
· Equipment design and
layout
· Job design and structure
· Anti-slip surfaces

36. Walking and working surfaces should be
free from trip and slip hazards

37. Robotics used in plate-glass handling reduces
ergonomic and laceration hazards

38. Machine guarding protects operators from
rotating shafts, belts or drive chains

39. Noise
Uses or sources of
exposure
to hazard
Potential effects
(physical hazards
or health effects)
Precautions or control
strategies
Pneumatic vibrators,
compressors, mixing
drive motors,
blowers and dust
collectors, conveyors,
packaging
equipment, etc.
Occupational
hearing loss,
communication
difficulty and stress
· Isolation, enclosure,
reflective barriers or sound
absorption materials
· Innovative design of
machine guarding
· Specifying lower-noise
motors or equipment
· Use of hearing protection
and a hearing conservation
programmer

40. Radiant heat, high-temperature work
environment
Uses or sources of
exposure
to hazard
Potential effects
(physical hazards
or health effects)
Precautions or control strategies
Heating or melting
processes during
maintenance or
emergency response
activities
Heat stress
or thermal
burns ,
heat cataracts
· Shielding ,barriers, reflective
surfaces, insulation
· Water-cooled equipment
· Air-conditioned control rooms
· Heat-protective clothing and
gloves
· Acclimatization to hot working
environments, intake of water
and electrolyte beverages,
controlled work-rest regimens

41. Quality-control technician taking glass samples from furnace and wearing
personal heat protective equipment and IR shielding glasses

42. Inhalation of airborne from raw material
(crystalline silica, clay, lime, iron oxide, nuisance dusts )
Uses or sources of
exposure to hazard
Potential effects
(physical hazards
or health effects)
Precautions or control strategies
Handling, Exposures
during routine
maintenance activities,
rebuilds
non-ventilated equipment
or mixing equipment
Raw materials are
extremely
abrasive, causing
deterioration of transfer
or storage system in
manufacturing processes
Range from
irritation to
chemical burns
to chronic effects
such as decreased
pulmonary
function, lung
disease,
pneumoconiosis
silicosis
·Equipment exhaust ventilation
· Proper material handling
· Isolation of operators
·PPE
· Active leak detection and
repairs
. Periodic medical screening,
surveillance and early
intervention based on
exposure

43. Heavy metals particulates or fumes (lead, cadmium, chromium,
arsenic, copper, nickel, cobalt, manganese or tin)
Uses or sources of exposure
to hazard
Potential effects
(physical hazard
or health effect)
Precautions or control strategies
As raw materials or impurities in
glazes, coloring agents
Maintenance and construction
activities involving soldering,
cutting, welding
Grinding, cutting, drilling
structural members or machinery
Heavy
metal
toxicity
· Engineering controls
· HEPA-ventilated portable power
tools
· Use of ventilated booths for spray
painting & coating activities
· Good work practices to reduce
airborne particulates( wet method)
· Personal hygiene, segregated
laundering of contaminated work
clothes
· Respiratory protection and
protective clothing
· Medical surveillance and biological
monitoring

44. Bases (sodium hydroxide) or acids (HCL,
sulphuric acid, HF)
Uses or sources of
exposure
to hazard
Potential effects
(physical hazards or health effects)
Precautions or control
strategies
wastewater
treatment and pH
control
Acid cleaning or
etching processes
with HF
.Corrosive to skin or
eyes
Respiratory tract and
mucous membrane
irritant
.HF causes severe skin
burns that can go
undetected for hours
· Process isolation
· Safe handling practices
· PPE use-respiratory
protection, rubber
gloves, faceshield with
eye protection,
eyewash/safety shower
· Exhaust ventilation to
control acid vapours or
aerosols

45. Propane, natural gas, gasoline, fuel oil
Uses or sources
of exposure
to hazard
Potential effects
(physical hazards or
health effects)
Precautions or control strategies
Fuels for
process heat
& powered
industrial
trucks
Fire and
explosion
hazards,
Exposure to
CO or other
products of
incomplete
combustion
· Proper design and inspections of
storage and distribution system, and
combustion process controls
· Safe unloading, filling and handling
practice
· Routine testing and control of
combustion processes

46. Inhalation of bioaerosols
Uses or sources of
exposure
to hazard
Potential effects (physical
hazards or health effects)
Precautions or control
strategies
Aerosol containing
bacteria, moulds or
fungus generated
from spraying process
or cooling water in
humidification
processes, ventilation
systems
.Waterborne
illness with
systemic non
specific flu-like
symptoms,
.fatigue
.Potential for
dermatitis
· Process design and mist
reduction
· Process and cooling
water treatment with
biocides
· Routine cleaning and
sanitization
· Elimination nutrient
source in water system
· Respiratory protection
· PPE, gloves and good
personal hygiene

47. Aerosols of reused waste water that is not
treated can cause waterborne illness

48. Demographics of injuries and illness
cases

49. Nature of occupational injuries and illnesses
lost workday cases 1994

50. Nature of occupational injuries and illnesses
lost workday cases1994

51. Body part affected in lost workday injury or
illness cases1994

52. Refrences
 Recognition of Health Hazard in Industry;
William A.Burgess
 Glass, Ceramics and Related Materials; Jonathan
P.Hellerstein
 Technical Approach to Glass ;M.B.Volf

54. Sources of occupational injuries and
illnesses lost workday cases