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Raw material pre-processing
Crushing block shaped raw materials: Crushing block shaped raw materials such as quartz sand, soda ash, limestone, feldspar, etc. to achieve a certain particle size requirement for better mixing and melting in the future.
Dry and Wet Raw Materials: Dry and remove moisture from wet raw materials to prevent defects such as bubbles caused by moisture evaporation during the melting process, which can affect the quality of glass.
Iron removal treatment: Iron removal can be performed on iron containing raw materials using methods such as magnetic separation to reduce the impact of iron impurities on glass color and transparency, ensuring the purity and quality of the glass.
Preparation of blending materials
Accurate ingredients: Accurately weigh various raw materials according to a certain formula ratio to ensure the precise and accurate dosage of each raw material, in order to obtain ideal chemical and physical properties.
Adequate mixing: Put the weighed raw materials into the mixer for thorough mixing, so that various raw materials are evenly distributed and ensure the consistency of the glass composition.
Melting process
High temperature melting: Place the mixed glass material into a tank kiln or furnace, and heat and melt it at a high temperature of 1550 ℃ -1600 ℃ to cause a series of physical and chemical reactions in the raw materials, forming a uniform, bubble free liquid glass that meets the forming requirements.
Clarification and homogenization: During the melting process, bubbles in the glass liquid will gradually rise and escape, and the glass liquid will be further homogenized through stirring, convection, and other methods to improve the quality and uniformity of the glass.
Forming
Blow molding method: For narrow mouthed bottles, blow molding is usually used. First, blow the molten glass into the initial mold to form a preliminary shape, and then transfer it to the final mold for a second blow molding. By controlling factors such as blowing pressure, time, and mold shape, ensure that the wall thickness of the bottle is uniform and the shape is accurate. Common methods include manual blowing and mechanical blowing. Manual blowing can create unique shapes and exquisite crafts, while mechanical blowing is suitable for large-scale production.
Compression method: Suitable for wide mouthed cans or containers with complex shapes. First, press the molten glass into the bottom shape, and then expand it into the desired can shape by applying pressure. This method can produce some special shaped glass bottles, such as square bottles, irregular bottles, etc.
Heat treatment
Annealing treatment: Glass bottles undergo drastic temperature and shape changes during the molding process, which can generate internal stress. Place it in an annealing furnace and slowly cool it under controlled conditions to eliminate or reduce the stress inside the glass, improve the strength and thermal stability of the glass bottle, and prevent cracking due to stress concentration during subsequent use, transportation, and storage.
Quenching: For some glass bottles that need higher strength, such as beer bottles and perfume bottles, quenching process can be used. The glass bottle, which is about to be formed, is rapidly cooled to create a layer of stress on the surface of the glass, thereby improving the strength and impact resistance of the glass bottle.
Surface treatment and decoration
Surface treatment: Surface treatment of glass bottles to remove possible defects such as burrs and burrs, making the surface smooth and flat. At the same time, polishing and other treatments can be carried out to improve the transparency and glossiness of the glass bottle.
Decoration process: Decorate glass bottles as needed, such as painting, screen printing, labeling, etc. Spray painting can give glass bottles different colors and appearance effects; Screen printing can print text, patterns, and other information on the surface of glass bottles; Labeling can indicate the name, specifications, ingredients, and other details of the product.
Quality Inspection and Packaging
Quality Inspection: Conduct strict quality inspections on the produced glass bottles, including inspection items such as appearance quality, dimensional accuracy, wall thickness uniformity, heat and cold resistance, internal stress, etc. By combining manual inspection with automated testing equipment, such as using infrared sensors to detect internal stress, laser scanning to ensure accurate bottle size, and computer imaging to detect defects that cannot be detected by the naked eye, we ensure that every glass bottle meets quality standards.
Packaging: Glass bottles that have passed inspection will be packaged, usually in cardboard boxes, plastic boxes, or pallets. The glass bottles are neatly arranged in the packaging container and necessary protective measures are taken, such as filling with cushioning materials, to prevent them from being damaged by collisions, compression, etc. during transportation.
