Glass Manufacture

ver. 1

ME 4210: Manufacturing Processes and 1

Engineering - Prof. J.S. Colton GIT 2011
 Overview
Hand glass manufacture
Sheet glass manufacture
Mechanical sheet glass manufacture
Pilkington float glass process
Bottle manufacture
Codd bottles
Ramune bottles

ME 4210: Manufacturing Processes and 2

Engineering - Prof. J.S. Colton GIT 2011
Hand Glass Manufacture

ME 4210: Manufacturing Processes and 3

Engineering - Prof. J.S. Colton GIT 2011
Hand Glass Manufacture

ME 4210: Manufacturing Processes and 4

Engineering - Prof. J.S. Colton GIT 2011
 French Glass
Factory

Glass Plate
Press

ME 4210: Manufacturing Processes and 5

Engineering - Prof. J.S. Colton GIT 2011
 Rolled glass
Single roll
Molten glass is poured onto a metal table and
a single metal roll is used to flatten it into a
sheet.
Double roll
Molten glass is passed between a pair of
rotating metal rolls to form the sheet.

ME 4210: Manufacturing Processes and 6

Engineering - Prof. J.S. Colton GIT 2011
 Cylinder Drawn Glass
The first mechanical method of drawing
glass, 40 ft high cylinders of glass were
drawn vertically from a circular tank. The
glass was annealed and then cut into 7
10 ft cylinders, which were then cut
lengthways, reheated and flattened. This
process was used in the UK up to the end
of the 1920's.

ME 4210: Manufacturing Processes and 7

Engineering - Prof. J.S. Colton GIT 2011
 Flat Drawn Glass
Molten glass is pulled vertically through a
slit in a large one-piece refractory block
that is floating on the glass surface.
The annealing lehr is mounted vertically
over the draw chamber.
The glass was drawn until it cooled
sufficiently to allow it to be cut.
The Belgians invented the original process
but it did not reach the UK until 1919.
ME 4210: Manufacturing Processes and 8
Engineering - Prof. J.S. Colton GIT 2011
 Flat Drawn Glass
Drawn glass is generally more pristine
than rolled glass because its surface has
remained untouched during forming.

ME 4210: Manufacturing Processes and 9

Engineering - Prof. J.S. Colton GIT 2011
 Single and twin ground polished
plate.
Glass is cast and then ground and
polished on a conveyor belt, to a fine
quality without distortion.

ME 4210: Manufacturing Processes and 10

Engineering - Prof. J.S. Colton GIT 2011
Float glass process

ME 4210: Manufacturing Processes and 11

Engineering - Prof. J.S. Colton GIT 2011
Float Glass Process

ME 4210: Manufacturing Processes and 12

Engineering - Prof. J.S. Colton GIT 2011
 Sir Alastair Pilkington
In 1952, Alastair Pilkington conceived the
idea of forming a ribbon of glass by floating
the melted raw materials at high
temperature over a bath of molten tin.
It took seven years and more than 7
million (80 million in today's money) to
develop the process.
Pilkington set out to replace the twin
grinding and polishing process for making
plate glass.
The float glass process superseded not
only that process, but also the sheet glass
process for making ordinary windows. It
was to become the universal process for
the manufacture of high quality flat glass.

ME 4210: Manufacturing Processes and 13

Engineering - Prof. J.S. Colton GIT 2011
Constituents of Soda-lime Float Glass
Raw Material %
Sand 72.6
Soda Ash 13.0
Limestone 8.4
Dolomite 4.0
Alumina 1.0
Others 1.0

ME 4210: Manufacturing Processes and 14

Engineering - Prof. J.S. Colton GIT 2011
Bottles - Blow-Blow Process

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Engineering - Prof. J.S. Colton GIT 2011
Ramune Bottles

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Engineering - Prof. J.S. Colton GIT 2011
Codd Bottles

Hiram Codd
1838-1877

ME 4210: Manufacturing Processes and 17

Engineering - Prof. J.S. Colton GIT 2011
 Codd Bottles
In 1870, Hiram Codd designed and patented a system for
keeping fizzy drinks in bottles with a glass marble
stopper.
When the bottle is filled, pressure in the bottle keeps the
marble against a rubber washer at the top making a seal.
To open the bottle, the marble is pressed down into the
neck chamber.
Tried changing marble shape to oval to dissuade children
from breaking the bottles to get the marbles.

ME 4210: Manufacturing Processes and 18

Engineering - Prof. J.S. Colton GIT 2011
 Ramune Bottle

In its early days, Ramune was sold in a bottle with a cork

cap wound tight with wire to keep the cork from popping
out.
In 1888, when Codd's patent rights expired, Tamakichi
Tokunaga, of Osaka, began developing a Ramune bottle
using a marble cap throughout Japan.
As to how the first soda arrived in Japan is another
question. Some think that it was Admiral Perry in 1853
while others believe it was on a British merchant ship in
1860. Whichever way I'm glad it is still around to enjoy.

ME 4210: Manufacturing Processes and 19

Engineering - Prof. J.S. Colton GIT 2011
Coca-Cola Bottle Molds

ME 4210: Manufacturing Processes and 20

Engineering - Prof. J.S. Colton GIT 2011
 Summary
Hand glass manufacture
Sheet glass manufacture
Mechanical sheet glass manufacture
Pilkington float glass process
Bottle manufacture
Codd bottles
Ramune bottles

ME 4210: Manufacturing Processes and 21

Engineering - Prof. J.S. Colton GIT 2011
 ME 4210: Manufacturing Processes and 22
Engineering - Prof. J.S. Colton GIT 2011