MBAA Rocky Mountain District Technical Summit June 25

MBAA Rocky Mountain District Technical Summit June 25, 2010 Everything’s Better in Glass Connie Maxwell, Quality Manager O-I Windsor, Colorado

Owens-Illinois, Inc. • Founded 1903 in Toledo, Ohio • Operating in 22 countries q 78 glass factories q 169 furnaces q 446 machines • 23, 000 employees Hot End, Windsor Plant, CO Owens-Illinois, Inc. Global Glass Industry Update 2

O-I Global Glass Profile O-I Europe #1 O-I North America #1 • 19 manufacturing plants • 6, 000 employees • 1. 2 million tons of recycled glass • 38 manufacturing plts • 8, 500 employees • 3. 0 million tons of recycled glass O-I Asia Pacific #1 • 10 manufacturing plants • 3, 500 employees • 0. 6 million tons of recycled glass O-I South America #1 • 11 manufacturing plants • 4, 600 employees • 0. 4 million tons of recycled glass

O-I North America Facilities 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Auburn, NY Crenshaw, PA Brockway, PA Toano, VA Danville, VA Winston-Salem, NC Atlanta, GA Zanesville, OH Lapel, IN Streator, IL Muskogee, OK Waco, TX Portland, OR Oakland, CA Tracy, CA Los Angeles Windsor, CO Brampton, Ontario Montreal, Quebec 19 18 13 14 15 16 17 10 9 11 12 7 1 2, 3 8 5 6 4

Why Everything’s Better in Glass • Infinitely recyclable with no loss of quality • No flavor or chemical transfer to contents of container • Takes less energy to re-melt a glass container than to melt the raw materials

The Glass Container Factory Batch and Furnace HOT END Forming Surface Treatment Selecting / Inspection COLD END Palletizing Carton Assembly Shipping

Batch House • Raw Material Unloading –Truck or Rail • Storage –Individual Silos • Batch weighing –± 0. 1 % Accuracy • Batch Mixing • Mixed Batch Transport

Batch composition: 1) Raw Materials 70% Sand 15% Soda Ash 12% Limestone Plus 3% Colorants and Oxidizers 2) Cullet Up to 50% recycled glass from internal plant sources and recycling centers can be used. Cullet aids in fuel efficiency and melting in the furnace.

Forming Machine Windsor Plant Oxygen Fueled Furnace Exhaust Flue Refiner Exhaust Ports (Fuel) Doghouse (Batch Delivery) Alcove Melter Ports (Fuel) Forehearth Throat End Wall Feeder Forming Machine

Furnace Interior Batch Delivery Melter Area Glass Flow Entry into refiner / alcove leading to forehearth Glass Flow

Glass Formation Approximate Temperatures (Degrees F. ) • Melting (Furnace) 2750 degrees • Conditioning (Forehearth) 2100 degrees. • Gob Formation / Forming 1700 degrees • After Formation (Softening Point) 1300 degrees • Lehr Entry (Annealing) 900 degrees

Batch and Furnace Feeder Forehearth After melting in the furnace, the glass flows into a forehearth where further conditioning takes place to prepare the glass for the forming process.

Feeder Glass is formed into “Gobs” by a ceramic tube pushing the glass through orifices or openings at the base of the feeder. The number of orifices is equal to the number of bottles produced on each section of the machine. TUBE

Feeder What is a gob? Diameters 3/8” to 4” Lengths ½” to 6” A gob is a specific amount of molten glass that will be formed into a glass container.

Forming Operations There are three phases to making a bottle once the gob leaves the feeder: 1. 2. 3. Delivery Equipment Blank Side of the Forming Machine Mold Side of the Forming Machine

Delivery Equipment Gob enters the delivery system at 1700 ºF Scoop: Routes gob to section that is ready Trough: Routes gob to proper deflector Deflector: Provides control of path of falling gob for exact alignment in center of blank. Gob delivered into the blank at 1300 ºF

Forming Machine 12 Section Quad On the Windsor machines, 12 Individual Sections produce 4 bottles at each section There are 4 cavities in each section. Each cavity has a unique number.

Forming • The gob is delivered into the blank mold side of the machine or the rear of the machine and is formed into a parison. • The parison will be formed by either the Press and Blow or the Blow and Blow process. • During the forming cycle, lubrication is manually applied to the blank molds and blow molds. Glasshouse Terms: • The “Parison” is sometimes called the “Blank”. • The technical name for the “Press and Blow” operation is “NNPB” - Narrow Neck Press and Blow • Applying lubrication to the molds is called “doping”.

What is a Parison? A parison is a specifically shaped formation of glass which will be blow up like a balloon in the blow mold to form the bottle. A parison has the following features: Finish Hollow inside Cooler skin or enamel on its outer surface Temperature of 1300 degrees F on its outer skin. The same amount of glass as the container it will produce

Parisons are formed on the blank side of an I. S. machine from the gob

Parisons greatly differ in shape for each process and are a precise shape for each type of bottle Parisons are created in three seconds for a typical 12 oz. container and are just barely able to hold their shape

Bottle Forming Cycle Narrow Neck Press and Blow Process 1) Gob Delivery 2) Start Press 5) Parison Reheat 3) Press 4) Plunger Down 6) Transfer to Blow Mold - Reheat 7) Parison Reheat and Run 8) Final Blow and Vacuum 9) Bottle Takeout 10) Bottle Cooling

Parison Formation Press and Blow Process 1. Gob entry 2. Start Press 3. Full Press

Parison Formation Start transfer Parison

Container Formation Parison transfer to mold Compressed Start pickup air applied Mold closes

Container Cooling Pickup and placement on cooling pad Cooling pad Fan air applied

Container cooling and transfer to conveyor cooling pad Cooling pad

Container transfer into annealing lehr Annealing lehr Tin spray coating application

Elements of an I. S. machine • Individual sections on the forming machine allows the ability to take one or more sections out of production for repairs without removing the other sections from producing containers for the customer. • Total time required to produce a container varies, but beer and soda bottles take approximately 10 seconds. • Each section can produce 1 to 4 bottles simultaneously. • Machines may have anywhere from 4 to 16 sections. • Depending on container size and shape, production speed may be as fast as 700 containers per minute.

Annealing & Surface Treatment Between the discharge from the forming machine and entry into the lehr to begin the annealing process, the first part of a two part surface treatment is applied to the container. After discharge from the forming machine, the bottle must be annealed. Annealing is the controlled removal of heat from the glass container

Surface Treatment 1) Surface Treatment protects the outside of the glass container by applying a lubricious (slick) surface on the outside of the container. 2) Surface Treatment is applied in two stages: Hot End: Tin oxide is vaporized onto the container after leaving the forming machine but prior to entering the lehr. Cold End: Polyethylene is sprayed onto the bottles at the lehr discharge.

Surface Treatment Hot End Application Tin is vaporized onto the bottles.

Annealing Lehr Cross sectional view Heating zones 1200 800 ºF 400 0 Cooling zones Typical annealing temperature curve Annealing point

Annealing The Glass Container What is the purpose of annealing? • To relieve internal stresses in the glass that are a result of uneven cooling of glass container during the forming process. • The outer surface of the container cools fast while inner surface cools slowly, creating the stresses.

Annealing The Glass Container How does the lehr anneal the glass? • Reheats the glass above 1050 ºF and holds this temperature until temperatures inside and outside the container equalize. After that, it slowly cools the container back to room temperature. How long does this preheating and slow cooling process take? • Depends upon the size and shape of the container • Times vary from 20 minutes to 90 minutes.

Annealing Lehr Discharge Polariscope 1) Samples are obtained immediately prior to the overhead sprays to check annealing in the “Polariscope” 2) Annealing is measured in gradients of 1 -5 “discs. ”

Annealing Strain Discs

Surface Treatment Cold End Application Polyethylene is sprayed between the rows of bottles. Backup sprays are also available should the first unit fail to apply treatment. A diffusion hood is used to keep spray from the bottom backup unit reaching the finish of the bottle.

Surface Treatment Spray Head Location Spray head must be below finish. Lehr conveyor mat Diffusion hood airflow must be sufficient to keep treatment off of the finish.

Inspection Automatic Bottle Inspection • 100 % of the glass containers are inspected in a series of sophisticated machines called FP’s or FPX’s. • Data is collected and monitored to allow ready access to trend analysis and defect detection.

Palletizing Methods CARTONS Various types of corrugated packages BULK Bottles are placed onto tier sheets and stretch wrapped with plastic.

QUESTIONS?