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Module 2

Glass Design and Testing

PPT – SE – Glass Metal and Textile based Packaging Material

Sagar S. Waghmare
Assistant Professor
Dept. of Printing & Packaging Technology,
SIES Graduate School of Technology

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 Recap/ Pre-requisite

Glass Applictions
• Packaging (jars for food, bottles for drinks, flacon for cosmetics and pharmaceuticals)
• Tableware (drinking glasses, plate, cups, bowls)
• Housing and buildings (windows, facades, conservatory, insulation, reinforcement structures)
• Interior design and furnitures (mirrors, partitions, balustrades, tables, shelves, lighting)
• Appliances and Electronics (oven doors, cook top, TV, computer screens, smart-phones)
• Automotive and transport (windscreens, backlights, light weight but reinforced structural components
of cars, aircrafts, ships, etc.)
• Medical technology, biotechnology, life science engineering, optical glass
• Radiation protection from X-Rays (radiology) and gamma-rays (nuclear)
• Fibre optic cables (phones, TV, computer: to carry information)
• Renewable energy (solar-energy glass, windturbines)

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 Content - Outcome

1. Introduction to Design of Glass

2. Specifications and Quality Control – Defects
3. Parts/Design of Glass containers

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 Design of Glass

• What comes to mind when we say design of glass…?

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 Bottle Design

• Wide mouth Bottles

• Narrow mouth Bottles

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 Neck and Shoulder Areas

• The impact on filling, air displacement, and dispensing.

Fill level in long narrow necks
Headspace for thermal expansion and facilitate filling.
• Manufacturing defect ---choke neck. Ridge on the sealing surface---overpress
• Upper shoulder --- below the neck.
• Shoulder and neck blending ---important design and production.
lower shoulder--- the integration point between the upper shoulder and the body.
Contact area

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 Sides

• The most generalized areas of the bottle.

• Labeling styles and preventing scuffing must be
considered. Bottles designed with label panels to prevent
scuffing.
• The panel may have prominent base and shoulder ridges.
• In angular bottles, rounded corners are preferable for
wraparound or three-side labeling.
• Spot labeling is normally a one- or two-sided
application.
• Labeling of non-round shapes is slower than for round
shapes

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 Heel and Base
• High-abuse area--- start high from the base curving into the base to a suitable base diameter.
• Body-to-base curve should combine 3 radii.
The largest blends body to heel, the smallest blends heel to base.
• Diameter as large as possible as a good design.
• Center of the base ensure a flat, stable bottom .
• Stippled or knurled on the circular bearing surface to protect the scratches
not to weaken the body during handling and usage.
• Ketchup bottles and other sauce bottles require:
heel and base be heavier and contoured when expelling the contents.
• Wide-mouthed jar bases have designed-in stacking features.
·Container base fits into recessed cap.
· Indented container base fits over cap.
• Heel tap --- excess glass distributed to the heel.

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 Closures/ Bottle caps
• Cap Closures/Closure design is
important to be understood while
designing glass bottles.

Source: CSP TRG AIDS - AUG 2008

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Lug type Closure

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Crown Type Closures

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 Roll-on Type

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 Defects in Glass
• There are six broad classifications of glass defects:
(1) Checks; (2) seams; (3) Non-glass inclusions; (4) dirt, dope, adhering particles, or oil marks; (5) freaks and
malformations; and (6) marks.
Defects can be grouped as:
• critical-those that are hazardous to the user and those that make the
containers completely unusable because they are freaks or did not completely fill the mold
• Major-those that materially reduce the usability of the container or its
contents
• Minor-those that do not affect the usability of the container, but detract from its appearance or acceptability to
the custom.

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 Critical Defects in Glass
• Critical Defects in Glass Bottles or Containers
[Link] Plug. A piece of glass, usually very sharp, projecting inwards just inside the neck bore.
[Link]. Is a defect where a small ridge of glass has been formed on the sealing surface of the
finish.
[Link]. An open crack starting at the top of the finish and extending downward.
[Link]. A small, shallow surface crack, usually at the bore of the container
[Link]. Odd shapes and conditions that render the container completely unusable. Bent or cocked
necks are a common defect of this type.
[Link] Distribution. Thin shoulder, slug neck, choke neck, heavy bottom are terms used to describe
the uneven distribution of glass.
[Link] Blister. A thin blister, usually found on or near the sealing surface.

It can however show up anywhere on the glass container.

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 Glass Bottle and Container defects continued..

[Link] Bore. Here excess of glass has been distributed to the inside of the finish or opening
[Link]. Partial fractures, usually found in the heel area.
[Link]. Any opening causing leakage. It occurs most often in bottles with pointed corners.
[Link]. A hair-like string inside the bottle.
[Link]. Spikes are glass projections inside the bottle.
[Link] Swing. Is a glass thread joining the two walls of the container

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 Some Minor Defects Commonly Found in Glass
Containers

[Link] Shoulder. Not fully blown, or sagged after blowing

[Link]. Similar to a check, but opened up. A tear will not break when tapped, a check will.
[Link]. A wavy condition of horizontal lines in the body of the bottle.
[Link] Blister. A deeply embedded blister that is not easily broken.
[Link]. Scaly or granular nonglass material.
[Link] Tap. A manufacturing defect where excess glass has been distributed into the heel
[Link]. A brush mark is composed of fine vertical laps, e.g. oil marks from moulds.
[Link] bottle. A wavy surface on the inside of the bottle.
[Link]. Small bubbles in the glass
[Link] ring seam. A bulge at the parting line between the neck and the body

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 Lecture 13

PERFORMANCE & TESTING

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 Performance and Testing requirement?
• It is important that containers comply with specification and general industry guidelines
in order to withstand the normal stresses and mechanical abuse right through until the end
user has finished using it.

• Testing’s for glass containers:

1. Alkalinity Test
2. Verticality/Stacking Testing
3. Annealing defects
4. Thermal Shock
5. Chemical Resistance
6. Constituents testing..

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 Alkalinity Test for Glass Containers
• Alkalinity is the measure of the ability of a solution to neutralize acids to the equivalence point of
carbonated or bi-carbonated.

• Alkalinity is normally given in the units mEq/L (Milliequivalant per liter), commonly given as ppm or
Parts per million.
• Alkalinity test is done to identify the quality of Glass

Type 1 – Powder Glass (Group1)

Type 2 – Water Attack Test (Group 2 Glass)
Type 3 – Powder Glass (Group 3 Glass)
Type 4 – Powder Glass (Group 4)

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 Alkalinity Test for Glass Containers Continued..
• The test is determined to determining the resistance to water attack (Resistance to Alkalies)
• The degree of attack depends on the amount of Alkali released under the influence of attacking medium
under the conditions specified (Alkali present in the water @ high temperature).
• The equipment used for this test should be of high accuracy and the environment should be free from
Dust/fumes in air.
• Autoclaves are generally preferred for this test.
• Other apparatus/chemicals required are;
1. Different sizes of Sieves
2. 250 ml Conical Flask
3. Desiccator
4. Permanent Magnet and Volumetric apparatus
Chemicals – Special Distilled Water, Methyl Red Solution

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 Procedure for Alkalinity test on Glass Containers
• Not less than six containers are used and each container must pass the test.
1 Fill the containers completely with warm water, empty and allow to drain for thirty seconds, removing the last drops of
water by touching the inverted rim with filter paper No. 41 (12.5 cm) Whatt-man.
2 Repeat the washing three times.
3 Fill the containers to their prescribed capacity with Acid Methyl Red Solution and seal on Ampoule Sealing Machine.
4 Heat in an autoclave at a temperature of 121°C for 30 minutes. Cool and examine the color of the solution
5 When the containers of are of colored glass, remove the solution for examination on a thoroughly washed while glazed
tile.
6 The container passes the test, if the color of the test solution has not changed form pink to the full yellow color of
Methyl Red as indicated by comparing it with the color of a solution prepared by adding 0.1 ml of 0.05 N Sodium
Hydroxide to 10 ml of Acid Methyl Red Solution.
7 The containers, which have once passed the test, may fail to do so after being stored.
8 A samples from a batch of containers which fails to pass the test after storage may be washed internally with a 5 percent
v/v solution of Glacial Acetic Acid followed by three washing with water, and resubmitted to the test.
9 If the sample then passes the test each container of the batch is similarly washed before being used.

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 Annealing Defects
• What is Annealing
• Annealing of glass is done to reduce internal stresses. In annealing oven;
- Walls are comparatively thick and cooling will not be even.
- The inner and outer skins of a glass become rigid
- The still-contracting inner portion build up internal stresses
- Uneven cooling develop substantial stresses in the glass.
- Bottle passes through an lehr after removal from the blow mold.
- LEHR is a belt passing through the controlled temperature oven at a rate of about 200mm to 300mm per
minute.
• Glass temp. is raised to 5650 C and then gradually cooled to room temperature with all internal stresses
reduced to safe levels in about an hour as they exit.
• Improperly annealed bottles are fragile and high breakage.
• Hot-filling also produce unacceptable breakage levels.

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 Stacking Strength
• Forces of this nature might be produced during capping or through stacking products on top of each
other.
• To help ensure glass containers have adequate vertical load strength, we test to BS EN ISO 8113-2004
using a Universal Testing Machine

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IMPACT TESTING
• To help ensure glass containers have an adequate impact resistance, we can test to
standard manufacturing codes of practice using an industry standard Pendulum Impact
Tester.

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 Thermal Shock

• Hot-fill or heat-treated glassware can be tested for thermal shock resistance to ensure the
product is fit for the intended purpose.
• Testing can be carried out to ASTM C149 and BS EN ISO 7459 either as pass/fail test typically at
42OC downshock or progressive testing to complete sample failure.

• Effect of sudden temperature change effect is minimal if both sides are heated or cooled
simultaneously effect is prominent when one surface is hot and the other surface is chilled

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 Coating Performance

• Assessment of surface protection can be carried out by use of slip tables and hot end coating
technology.
• The longevity of the coating performance can be assessed using line simulator, where bottle to
bottle abrasion damage which may be expected to occur on a filling line can be replicated and the
subsequent damage of the container tested.
• This is of particular use for returnable glassware.

Source: [Link]/CSP TRG AIDS - AUG 2008

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 Internal Pressure Resistance

• Carbonated beverage bottles need to be able to withstand without failure the

pressure produced by their contents over long periods.

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 On-line Inspection Of Glass Bottles

1. Bottle Spacer. This machine is pre-set to create a space between the bottles on the conveyer to
avoid bottle to bottle contract.
2. Squeeze Tester. Each bottle is passed between discs that exert a force to the body of the container.
Any obvious weakness or crack in the bottle will cause it to fail completely with the resulting
cullet being collected by a return conveyor running underneath.
3. Bore Gauger. The internal and external diameter at the neck finish entrance to the bottle and the
bottle height are measured.
Bottles outside specification are automatically rejected by means of a pusher positioned downstream
from the gauger.

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 On-line Inspection Of Glass Bottles

• 4. Check Detector. Focuses a beam of light onto areas of the container where defects are known to occur
from previous visual examinations, any crack will reflect the light to a detector, which
will trigger a mechanism to reject the bottle.
5. Wall Thickness Detector. This test uses dielectric properties of the glass, the wall thickness can be
determined by means of a sensitive head which traverses the body section of the container.
A trace of the wall thickness is then obtained and bottles falling below a specified minimum will be
automatically rejected.
6. Hydraulic Pressure Tester. A test carried out on bottles which will be filled with carbonated beverages
and gauges the internal pressure of every bottle before it is packed.

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 Engineering Properties of Glass

[Link]
[Link]
[Link]
[Link]
5.U value
[Link] property

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 Transparency of Glass
• Transparency is the main property of glass which allows the vision of the outside world through it.
The transparency of glass can be from both sides or from one side only.
• In one side transparency, glass behaves like a mirror from the other side.

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 4. Transmittance
3. Workability of Glass
A glass can be molded into any shape, or it can be blown during melting. So, workability of glass is
a superior property.

The visible fraction of light that passing through glass is the property of visible transmittance.

When glassware is stored for several months where fluctuations of temperature and humidity cause
condensation, salts are dissolved out of the glass, a condition called “blooming”.

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 5. U value of Glass
• U value represents the amount of heat transferred through glass.
• If a glass is said to be insulated unit then it should have lower u value.

• 6. Recycle Property of Glass

• Any glass can be 100% recyclable.
• It can also be used as raw material in construction industry.

Image Source: [Link]

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 2. Strength of Glass
• The strength of glass depends on the modulus of rupture value of glass.
• In general glass is a brittle material but by adding admixtures and laminates we can make it as more
strong.

Image Source: [Link]

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Glass Bottle Design- Defects

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 Homework/ Task for today

1. Suggest what type of closures are used in pharmaceutical syrups?

2. Observe glass bottles of Sauce/Rooh-Afza base and discuss the
design considerations made.
3. Discuss the Jab bottle design considerations.

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 Refence(s)

• The Packaging User’s Handbook by F.A. Paine

• Handbook of Packaging Engineering – 3rd Edition
• The Wiley Encyclopedia of Packaging Technology
• Google Classroom

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