GLASS BOTTLE MANUFACTURE PDF

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INDUSTRIAL TRAINING REPORT. CHAPTER ONE 1.0. INTRODUCTION 1.1. STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (S.I.W.E.S) The Student Industrial Work Experience Scheme (S.I.W.E.S) was established by the Industrial Training Fund (ITF) in 1973. It was instituted in order to provide the opportunity for stud...

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INDUSTRIAL TRAINING REPORT.

CHAPTER ONE 1.0. INTRODUCTION 1.1. STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (S.I.W.E.S) The Student Industrial Work Experience Scheme (S.I.W.E.S) was established by the Industrial Training Fund (ITF) in 1973. It was instituted in order to provide the opportunity for students in tertiary institutions to gain a hands – on experience in their field of study before the completion of their program in their respective institutions and also to correct the general deterioration in the quality of graduates from Nigerian universities, caused by lack of equipment in the university laboratories. The primary aim of the S.I.W.E.S is to bridge the gap between the knowledge acquired in the lecture room and the skills required in the work place. This training usually varies from a period of three months to one year depending on the level, institution, and course of study. The bodies involved in the management of S.I.W.E.S. are the Federal Government and Industrial Training Fund (ITF). Other supervising agents include the National University Commission (NUC), National Board for Technical Education (NBTE) and National Council for Colleges of Education (NCE). Therefore the success of the SIWES depends on the efficiency of the ministries, ITF, institutions, employers of labor and the general public involved in articulation and management of the program. Thus the evaluation of SIWES in tertiary institutions in meeting up with the needs for the establishment of the program is necessary. In compliance with the aims and objectives of the S.I.W.E.S program, I carried out my Industrial Training (I.T) in Beta Glass Plc (Guinea Plant), a subsidiary of the Frigo Glass Group. I was assigned to the Quality Assurance department (Chemical laboratory section) where I carried out various analysis on both raw materials and manufactured products in the laboratory. I was also given an opportunity to tour various sectors of the factory to observe and hence, gain a general idea and experience of their operations. The activities carried out in the quality assurance department are of immense value to a materials and metallurgical engineer.

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1.2. OBJECTIVES OF THE S.I.W.E.S BODY The Industrial Training Funds policy Document No. 1 of 1973 which established SIWES outlined the objectives of the scheme. The main objectives of S.I.W.E.S are as follows:

 To provide an avenue for students in higher institutions of learning to acquire industrial skills and experiences during their course of study.  To prepare students for industrial work situations that they are likely to meet after graduation.  To expose students to work methods and techniques in handling equipment and machinery that may not be available in their institutions.  To make the transition from school to the world of work easier and enhance stude ts’ contacts for later job placements.  To provide students with the opportunities to apply their educational knowledge in real work situations, thereby bridging the gap between theory and practice.  To enlist and strengthen e plo ers’ involvement in the entire educational process and prepare students for employment in Industry and Commerce (Information and Guideline for SIWES, 2002).

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1.3. COMPANY PROFILE Beta Glass Plc (Guinea Plant) is a subsidiary of Frigo Glass Industries Nigeria Limited and also a member of Leventis Group worldwide. It is a Nigeria-based company located at Km 32, Lagos- Badagry Expressway, Agbara Industrial Estate, Ogun State. The Company was incorporated on the 26th of June, 1974 through the equity participation of Metal Box Overseas Reading, England, Toyo Glass companies, Japan and Nigerian investors. The Company was listed on the exchange since 1986. In 1992, the company acquired the assets of the former African Glass located at Ikeja, Lagos state, Nigeria. Beta Glass Plc (Guinea Plant) formerly known as Carnaud Metal Box Toyo Glass is now the leading manufacturing company producing hollow glassware in Nigeria.The company has manufacturing plants in Agbara, Ogun state and in Ughelli, Delta state. It also has three furnaces with a capacity of approximately 600 tons of produced glass containers per day. The Company exports to 13 countries including: Angola, Benin, Burkina Faso, Cameroun, Gabon, Gambia, Ghana, Guinea, Liberia, Mauritius, Rwanda, Sierra Leone and Togo. The Company provides packaging solutions to a range of customers operating in the soft drinks, beer, spirit, cosmetics and pharmaceutical market segments.

PRODUCTS Beta Glass Plc (Guinea Plant) is engaged in the manufacture, distribution and sale of glass bottles and containers for the leading breweries, soft drinks, wine and spirit, pharmaceutical and cosmetics companies. The major products manufactured during my I.T. attachment include 35cl Ultra Sprite bottle, 75cl Star bottle, Eagle Aromatic Schnapps, Veleta wine bottles and Hero bottles.

MAJOR CUSTOMERS The o pa ’s ajor usto ers i lude breweries, soft drink bottlers such as Coca cola and maltina, distilleries, cosmetic companies and drug manufacturers. Page | 3

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QUALITY RATING Beta Glass Plc (Guinea Plant) has been rated the best in Nigeria and has won the standards organization of Nigeria (NIS) award for many years and running.

BETA GLASS PLC (GUINEA PLANT) MISSION STATEMENT To be the leading manufacturers of glass containers and household wares in Nigeria and the West African Sub region through improvement and total commitment to QUALITY and good employee relations and customer satisfaction whilst ensuring optimum returns to the stakeholders.

1.4. QUALITY CONTROL DEPARTMENT The Quality Control department is often referred to as the backbone of the company. This is because it forms a strong interlocking connection with every other department in the company. In Beta Glass PLC (Guinea Plant), the Quality Control department is divided into two sub sections. These sections are: a) Chemical laboratory department. b) Physical laboratory department. These two sections are in charge of ensuring optimum product quality. They each have their department representatives and are both headed by the Quality Assurance Manager (QAM). For the duration of my I.T. I was assigned to the chemical laboratory section under the Quality Control department.

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1.5. BETA GLASS PLC. (GUINEA PLANT) ORGANOGRAM

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1.6. CHEMICAL LABORATORY DEPARTMENT The chemical laboratory department is a sub–division of the Quality Assurance department. It is delegated with the following responsibilities; 1. Inspection of raw materials brought in from external sources. 2. Analysis of raw materials in use. Some of these analysis include: i. Moisture content determination of in-use raw materials. ii. Chemical content determination of in-use raw materials e.g. Iron, Alumina, Silica, Calcium oxide (CaO), Magnesium Oxide (MgO), etc. iii. Grain size distribution of raw materials in-use. 3. Analysis on glass products. These analysis include: I. Colour transmittance using a spectrophotometer. II. Applied colour label test. III. Glass density. 4. Density determination of fuel sources at the point of entrance into the company 5. Monitoring and treatment of water used in the company. There are seven different water samples analysed each day. These include: raw, process treated, compressor cooling, shear spray, forming drinking, canteen treated, and effluent treated water. The hardness and PH of these various water samples are monitored each day and treated when necessary to ensure proper dissolution and mixing of the raw materials.

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SPECTROPHOTOMETER

PH METER

WATER DISTILLER

METTLER TOP LOADING BALANCE

MUFFLE FURNACE

ELECTRIC OVEN

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DENSITY COMPARATOR

GRAIN SIZE SEIVE

ANALYTICAL WEIGHING BALANCE

FUME EXTRACTOR

FIG 1.0: IMAGES SHOWING CHEMICAL LABORATORY EQUIPMENT Page | 8

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1.7. CHEMICAL LABORATORY ORGANOGRAM

CHEMICAL LABORATORY MANAGER

ASST. CHEMICAL LAB. MANAGER/ANALYST

LABORATORY SUPERINTENDANT/ ANALYST

LABORATORY ATTENDANT

MATERIAL QUALITY SUPERINTENDANT

INCOMING MATERIAL SUPERVISOR

PACKAGING/WATER QUALITY SUPERVISOR

ENTRANCE CONTROL INSPECTOR

WATER TREATMENT INSPECTOR

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CHAPTER 2 2.0. GLASS Glass is an inorganic amorphous solid material that is usually transparent or translucent as well as hard, brittle, and impervious to the natural elements. Defined according to modern scientific beliefs, glass is a solid material that has the atomic structure of a liquid. Following a definition given in 1932 by the physicist W.H. Zachariasen, glass is an extended, three-dimensional network of atoms that form a solid which lacks the long-range periodicity (or repeated, orderly arrangement) typical of crystalline materials. Simply stated, glass is a super cooled liquid. Glass has been made into practical and decorative objects since ancient times, and it is still very important in applications as disparate as building construction, housewares, and telecommunications. It is formed upon the cooling of a molten liquid in such a manner that the ordering of atoms into a crystalline formation is prevented. Instead of the abrupt change in structure that takes place in a crystalline material such as metal as it is cooled below its melting point, in the cooling of a glass-forming liquid there is a continuous stiffening of the fluid until the atoms are virtually frozen into a more or less random arrangement similar to the arrangement that they had in the fluid state. Conversely, upon application of heat to solid glass, there is a gradual softening of the structure until it reaches the fluid state. This monotonically changing property, known as viscosity, enables glass products to be made in a continuous fashion, with raw materials melted to a homogeneous liquid, delivered as a viscous mass to a forming machine to make a specific product, and then cooled to a hard and rigid condition. The varieties of glass differ widely in chemical composition and in physical qualities. Most varieties, however, have certain qualities in common. They pass through a viscous stage in cooling from a state of fluidity; they develop effects of color when the glass mixtures are fused with certain metallic oxides; they are, when cold, poor conductors both of electricity and of heat; most types are easily fractured by a blow or shock and show a conchoidal fracture; they are but slightly affected by ordinary solvents but are readily attacked by hydrofluoric acid. Page | 10

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2.1. WHY USE GLASS AS A PACKAGING MEDIA? Glass is chiefly preferred as a packaging media on account of its many properties. Some of these properties are discussed below. 1. IMPERMEABILITY - Glass is impermeable to gases and moisture vapour. This property is important for all food and beverages and in particular wine and jam/comfiture. For wine, impermeability protects the wine from being contaminated by the odours of the ambient and from losing the organoleptic properties which is important for the long term storage of quality wines (mainly red). Glass products also cannot be perforated by syringes and this is a big advantage to avoid and prevent product boycotting and bio-terroristic attacks. This is nowadays a more and more important issue for the food Companies. 2. TRANSPARENCY: the consumer can immediately see the colour of the product before buying it. Normally bottles for red wines are dark to protect wine from light, mainly ultraviolet component of sunlight which is responsible of the oxidation of coloured o po e ts of red i es. White a d rose’ i es use either transparent or light dark bottles because of lower coloured components content. For jam, transparent containers are used, since the effect of light is not a big issue. 3. RIGIDITY - this ensures the shape ad volume stability of the product both under vacuum (e.g. jams) or under pressure (e.g., sparkling wines). Rigidity implies also that wine bottles and jam jars are not deformed during transportation handling and volume declared on the label is reliable. 4. RECYCLABLE: one major advantage of glass is that it can never go to waste. Even after it has served it service use, it can still be recycled as cullet and used in manufacturing other glass products. During manufacture of glass products, the defective products can be recycled as cullet thereby saving cost. Other reasons for glass use include its chemical durability, low thermal insulating properties, unreactive nature, long shelf life, etc. Page | 11

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2.2. DISADVANTAGES OF USING GLASS AS A PACKAGING MEDIA. 1. WEIGHT: a bottle of sparkling wine can weigh up to 750 grams (which is roughly equal to the weight of the product!). A PET bottle, on the contrary, can weigh less than one tenth (75 grams). In addition to that, PET bottles can be transported as a pre-form having a much lower volume of the final content. 2. BREAKABILITY: this has an adverse effect on both operators health during manufacturing and handling operations and, much more important, on the final consumer, in case of glass fragments inside bottle coming either from a manufacturing defect or from broken edge during filling. 3. NOISE GENERATED DURING FILLING OPERATIONS: this issue is nowadays achieving an increasing importance, mainly in Europe and US, where laws establish limits for the noise in production departments and unions are very sensitive to this issue! 4. WATER FOOTPRINT: i.e., the quantity of water needed to produce a bottle of glass. High demand of water needed in production process, mainly for cooling. This is a restri tio fa tor for areas of lo ater a aila ilit . Water footpri t is ha ing an increasing importance in those countries of environmental friendly culture.

FIG 2.0: Image showing products manufactured by Beta Glass Plc.(Guinea Plant)

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CHAPTER 3 3.0. MANUFACTURING PROCESS FOR GLASS BOTTLE CONTAINERS. There are three ajor stages i ol ed i the a ufa ture of glass produ ts. The i lude:  Ra aterials  Hot e d pro esses  Cold e d pro esses

3.1. RAW MATERIALS FOR GLASS CONTAINER MANUFACTURE Raw materials are the heart and core of any manufacturing company. This is due to a fact that no product can be manufactured without the availability of its necessary raw materials. Care must also be taken to ensure that the raw materials meet standard specifications required for the manufacture of top quality products. This stage demands dire attention because if the raw materials brought in fall short of the standard specifications then the manufactured glass products would have a high tendency to be defective resulting in energy and time wastage as well as waste of funds and resources. The raw materials brought in for glass bottle production are summarized in the table below with their respective sources included.

TABLE 3.0: RAW MATERIALS AND THEIR VARIOUS SOURCES RAW MATERIAL Coal (Pulverized) Cullet Dolomite Feldspar Iron chromite Iron oxide Limestone Sand Soda ash Sodium sulphate

SOURCE Enugu, Kogi In-house, Kaduna, Kogi, Ogun, Sokoto Edo, Kogi, Ogun Borno, Ekiti, Kaduna, Ogun Imported: South Africa Itape Ogun, Oyo, Edo, Kogi Owode, Ilaro, Afo Imported: China, Romania, Turkey Imported: Germany

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Feldspar

Soda ash

Sodium sulphate

Raw sand

Iron oxide

Pulverized coal

Limestone

Glass cullet

Iron chromite

FIG 3.0: Image showing raw materials for glass bottle manufacture Page | 14

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3.2. ROLES OF VARIOUS RAW MATERIALS IN GLASS CONTAINER MANUFACTURE. 1. CULLET: A glass batch may consist of 25 to 60 percent cullet by volume. Cullet is crushed glass, generally of the same composition as the mineral mixture, and comes from regrind from previous production runs and recycling sources. It is included because its characteristic of melting in the furnace before the other i erals helps a elerate the at h’s rea tio i to olte glass. It is a important energy savings ingredient that both lowers the amount of energy needed for the melting process and in turn helps reduce greenhouse gas emissions. The cullet brought in usually consist of green, amber and flint glass pieces. In summary cullet can be referred to as recycled glass that helps reduce the amount of raw materials and energy needed to make new glass. 2. DOLOMITE (CaMg(Co3)2: This is an anhydrous carbonate mineral composed of calcium magnesium carbonate. It is a source of magnesia which reduces devritification while reducing setting rate. 3. FELDSPAR: this is one of the minor raw materials used in glass making. Alumina (Al2O3), one of the major ingredients in feldspar gives the glass bottles their chemical resistance. 4. IRON CHROMITE: this gives the glass products their green colouring. 5. IRON OXIDE: this gives the glass products their amber colouring. 6. LIMESTONE (CACO3): this material is usually brought into the batch house in powdered form. It usually contains some impurities such as iron oxide and magnesium oxide (MgO). Its serves as calcium to the glass bottle i.e. it gives the glass bottle its strength, renders it more viscous at forming temperature, improves resistance to weathering and shortens setting time. The addition of lime (calcium oxide, CaO), supplied by the limestone, renders the glass insoluble, but too much makes the glass prone to devitrification - i.e., the precipitation of crystalline phases in certain ranges of temperature. Page | 15

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7. SAND (SIO2): this is a base material required for the production of glass bottles. It usually contains about 99.8% Silicon oxide (SiO 2) and some impurities in minute amounts. The impurities may include dirt, alumina (Al2O3) and Iron oxide (Fe2O3). 8. Soda ash (Na2CO3): also known as sodium carbonate. This material plays a vital role as it acts as a flux. It makes available the fluxing agent sodium oxide which reduces the melting point of the silica in the glass batch. 9. Sodium sulphate: this material prevents scum formation in the molten glass during refining and also acts as a flux for the molten glass. It equally acts as a fining agent in molten glass, removing small air bubbles and imperfections during the blowing and casting process. 10.Coal: the coal is always brought in a pulverized form. This provides a carbon source required for the glass colouring agents.

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3.3. GLASS MAKING OXIDES. TABLE 3.1: GLASS MAKING OXIDES Network formers (Acidic) SiO2 B2O3 GeO2 P2O5 V2O5 As2O3 As2O5

Network modifiers (Basic) MgO Li2O PbO CaO SrO Na2O K2O

Intermediate formers Al2O3 Sb2O3 Zr2O3 TiO2 PbO ZnO

 Network formers: can be produced by glass themselves. These are oxides of such elements whose atomic diameters are such that they can be surrounded by 4 oxygen atoms each in the form of a tetrahedron. They form chains and networks that they may exist in a completely random manner. All these on melting can give glass without the addition of any other oxide.  Network modifiers: to this class, being large number of elements whose atoms have large diameters and therefore, can have more than 4 oxygen atoms as the nearest neighbors; in other words the coordin...