What Is The Glassware Manufacturing Process?

Rowell GLASSWARE is a production and sales integrated company producing premium glassware, including drinking glasses. We own four Chinese energy-efficient multi-channel fine white material kilns and a total of 25 assembly lines that are high-tech. Our annual production around 1 million tonnes of glassware that is high-quality, with a an average daily output of around 950,000 pieces.

If you're looking to learn the entire fabrication of glasses this article will guide you through this highly-technical manufacturing process.

Raw Materials Of Glasswares

The primary raw materials used in making glasses is silica sand, sodium carbonate limestone, and various other auxiliary materials. In general, we would say the glassware we use is soda lime glass.

Silica Sand

Silica sand is the primary base material used to make glasses comprising over 70 percent of the raw materials used in the totality of glass. Silica sand, a mineral mostly composed of silica that is resistant to high temperatures and chemical stability. It's which is difficult to be damaged by chemical agents, whereas silica sand is more affordable, making it the best base material to use used in glass production.

Sodium Carbonate

The main ingredient is sodium carbonate, which is an alkaline oxidizer that is used for glass. When temperatures are high the sodium carbonate dissolves silica sand and trigger the creation the glass that is liquid. glass materials. In the process of sintering sodium carbonate may reduce the amount of bubbles within the glass and increase the clarity as well as quality glass.

Limestone

Limestone is used primarily to degass glass. In the process of making glass making, the proper amount of limestone will absorb and eliminate carbon dioxide, oxygen along with other harmful gases which can prevent bubbling inside glass. glass. In addition during the process of making of glass limestone is also able to enhance the toughness as well as wear-resistant of glass.

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Other Auxiliary Materials

In addition to these principal raw materials, the manufacturing of glass requires the addition of additional auxiliary substances, comprising sandy auxiliary materials, coloring agents, oxidizing agents, and others. These materials can alter the texture, color and the transparency of the glass and also alter the physical properties, as well as to increase the resistance to heat and impact resistant of glass.

Rowell Glassware Raw Material Workshop

Molds For Glassware Manufacturing

To make various shapes and types of glass, we have to create and design molds. Thus high-quality glass products is largely connected to the quality of the material, its the structure, the accuracy of processing and the maintenance on the moulds.

Let's consider the pressing machine for glass as an illustration. The main characteristics of press molds is that the punch is responsible for the form of glass products and the internal cavity of the mold decides the shape of the glass.

We typically utilize the mold material, which is cast iron. Its casting properties are excellent cheap, inexpensive hot, non-stick and makes it the most affordable choice. Today, a large portion of our clients require a custom design casting molds made of cast iron.

Based on our operating table for disc machines the machine must be fitted with 24 molds, three pairs of punches, three lids. This set of molds could most likely make 50 to 80 million glasses. The mold is created using CNC machine which is required to ensure the quality and precision in the creation of mold. Once the mold has been processed it must be treated with heat, such as tempering, quenching and so on. for enhancing the durability and resistance to abrasions that the mold has.

Glassware Molds

Prior to beginning production in full, we will need to set up the mold in order for trial production. change the mold every 2-3 hours after the glass is thought to be stable. A team from our Inspection Department will monitor every step of the process until the glass is completed. It is crucial to ensure that the glass is produced in a qualified manner.

The Specific Glassware Manufacturing Process

Melting of Glass Raw Materials

Raw materials include those previously mentioned, however each manufacturer's formula ratio is unique to each. This makes each individual piece of glass cup a unique piece. For instance the color of the transparent cup varies greatly. One may be super white and clear, whereas another is cloudy and appears grey. Since I am an expert on this field we can often identify the producer of one glass by its glass color and the surface.

Workers will pour a certain percentage that the material is in in addition to the broken glass to the large hot glass melting furnace to melt. This process requires that the furnace's temperature and the time of melting must be monitored to ensure there is a guarantee that glass ingredients are fully melt and all the components are equally dispersed.

Glass Molding

Once the melting process has been completed it will then get to the cutting area through the channel downstream.

Then the melted glass material is placed into the inside chamber of the mold. using the punch press and the glass cup will initially made into a shape. Once the glass material enters the mold, the turning table continues turning. Each mold will be rotated in the exact location of the tunnel downstream.

Production Plateform

The mold's plateform is fixated using one or more gas lances in order to make the mold warm. The spray gun may be rotated 360 degrees to accomplish the desired smoothness, and with no burr.

Fire Gun For Glassware Polishing

Annealing Process

Following the polishing process is completed, the machine takes the glass cup from the container, and then is placed onto the conveyor belt. The glass cup will be put into an annealing kiln that is long which keeps the rapid cooling from breaking the glass surface or causing cracks. The slow cooling and annealing process eliminates stress, enhances the strength and stability and guarantees the high-quality of the glass cups.

Annealing Furnance

Quality Inspection of Finished Glassware

After the glass goes through the annealing furnace, it is then taken onto the inspection station for quality. On every production line, three to four people will be assigned to check the glass products and packing.

Here's the video on glassware manufacturing, which will help you understand the process.

Possible Glassware Quality Problems

· Bubbles bubbles appear in the walls or at the inside of the glass either big or small.

Solutions: Mix all the components well, and adjust the proportion of raw materials and maintain the temperature and pressure within the kiln.

· Deformations: Most often, they appear in the round cups that have a round mouth and a deformed body.

Solution: Examine the molds, then replace the molds that are not damaged in time and then repair the new molds.

· Unknown mixture: There is white flecks of flocculents within the glass.

Solution: The glass isn't fully melted. It is better to reduce the amount in broken glass and allowing the melting complete.

· Surface roughness: The glass surfaces are soiled with oil or water ripples or any other substances. For glass that is open-molded your seam lines are extremely precise.

Solutions: Increase the quantity of gas sprayers to increase polishing.

· Broken glass Broken glass the glass is broken or damaged.

Solution: Drop it in the garbage collection bin.

Packaging Options of Finished Glass Products

Pallet Packaging

Pallet packing option is perfect for glassware that requires additional processing.

The pallet is place an enormous tray of paper on the bottom. Then, workers place the glasses one at a time in a neat manner. After the first layer is done, they place another large paper tray on top. Layer upon layer, one pallet can be set at a height of one meter. We then wrap the glass pallet with plastic film. This helps keep all glasses secure. Next, having workers bring it to the storage by using an trailer.

Carton Packaging

Certain customers only require transparent glass products. Customized packaging boxes must be designed 15 days in advance of when the product is launched and is delivered to our warehouse for packaging. When the products are produced and have passed quality testing They can then be placed into the cartons. The cartons are placed neatly on pallets and then covered in stretch film and stored in a warehouse.

Carton Packaging

In the process of making the different clients will have their own demands. For example If a client needs labels for each glass We can set up our automated labeling machines to address the issue. To remind the client by the client, they must supply the labels ahead of time. We can also customize labels to the specifications of the customer.

Automated labeling machine

Carton Packaging Types

Carton with divider: This kind of carton is suited for products that require additional packaging and can be used as a transport box. The benefit in comparison to pallets is transit boxes are able to dramatically reduce the amount of breakage of the products. The cost of the boxes are also reasonable.

For glassware of small and medium size like shot glasses, whiskey glasses, mugs and beer glass, this method of packaging drastically reduces the costs of procurement. The majority of the external containers that are designed for exports from foreign countries are constructed of five layers of corrugated papers, which are strong enough to withstand straight container loading, without the danger of damage.

Mass Production Carton Packaging

The inner box is paired with the outer carton This approach offers better protection to the glassware, and in essence removes any damage to the product.

For glasses of medium size The box inside typically has six pieces. Likewise, the outer carton may hold eight boxes, which total 48 pieces each carton. This method of packaging helps keep the weight of each container to under 20 kilograms.

for larger size, like glass bottles for beer A box can hold up to 24 pieces. To control costs, the interior boxes are constructed from three layers of corrugated papers, and can be printed with information specific to the customer The outer box can be customized by adding shipping marks.

6pcs Brown Inner Box

About the box If a customer demands that the product be delivered directly to the customer in boxes, the outer boxes could be constructed of colored box material. Because a vibrant packaging box and branded with the information of the buyer will more likely make purchases from consumers.

Shot Glass Inner Box Packaging

Additional requirements For gift shops, it is possible to select individual colored boxes. This is another an effective way to boost the volume of sales.

Rowell Glassware provides customized glasswares for a variety of occasions.

Our main items are made by machines, glasseswares, glass cups, glass drinkwares and tablewares for domestic or kitchen uses. These glasses include glass tumblers glass whiskey glass, mugs shot glasses glass Candy jars glass bowls and beer glasses, among others.

We also suggest the best packaging method that is based on the various kinds of sales, including various display boxes, including tags, stickers, etc.