Process

 

The process involved in manufacturing glass is a complex one with many intricacies. The accuracy and precision with which each step is carried out determines the quality and durability of the final product.

To start with, raw materials comprising mines produced minerals, manufactured chemicals and cullet are checked thoroghly to ensure that they are up to the mark in quality. They are then collected at the batch house, the starting point of the glass manufacturing process. Sourcing of superior raw material, their processing, handling and mixing are crucial in production of quality glass containers.

Depending on the customer requirement, the raw material for Amber ,Green or Flint glass is sent to the melting furnace from the batch house. AGI has ensured an excellent supply source for its inputs and has enabled computer control for the operations in batch house like storage, transport, mixing and charging into the furnace.

The mixture passes through three main parts of the furnace - the melter, the refiner, and the forehearth. The melting temperature in the furnace is around 1580 degrees. The molten glass flows through the refiner out along the forehearth. There, it is carefully cooled to a desired temperature and viscosity.

The molten glass now flows through different channels to the feeder and a shearing device cuts the glass flow as it exits from there. The shearing creates a specific amount of molten glass, known as a gob, which will be formed into individual containers. The gob now travels down to the Individual Section Machine (IS machines) through the gob distributor device.

IS machine comprises of multiple, identical forming sections with independently-controlled operating variables. The machines are available in several configurations to suit specific production requirements. Each IS machine is capable of producing a wide range of glassware. Production rate depends on the bottle shape & size. The state of the art machines are computer controlled to ensure precise process requirements .

While in IS machines, glass is malleable. To change its mechanical properties and make it usable, it is then sent through an Annealing Lehr. Annealing is a heat treatment process, in which glass is exposed to an elevated temperature and slowly cooled to relieve internal stresses.

From the Lehr, finished bottles go for a multi step online inspection process. AGI employs the best equipment for physical property testing of glass bottles such as AGR thickness tester, Ramp pressure tester, Vertical load tester etc..

Bottles that pass the test of quality move on to the packing area where customized packing is done as per the requirements of the specific customer. An exclusive in house design team at AGI ensures that our customers get various options to choose from and make their product look different