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The role of glass cannot be overestimated in modern life. From jars and bottles to different technologies and arts, glass is an integral component. Glass products include water vessels, decorating articles, bottles, spectacles, flasks, laboratory items, incandescent bulbs, fluorescent tubes, and several other items direct or indirect use in our routine life. When you find glass in such a vast variety, the question arises, "How is glass made?" Despite its ubiquity, only a few people think about the complex process of manufacturing of glass. This article explains how glass products are manufactured and what producers, techniques, and advanced technologies are used in glass-making.
Allow FEEMIO to share the glass manufacturing process so you can better understand how glass is produced in the industry and how it comes into your life.
The glass manufacturing process starts with properly selecting raw materials. The raw material that is widely consumed in glass manufacturing is silicon dioxide. Silicon dioxide is the primary raw stone and glass material available abundantly on Earth. The proportion of silica in each stone may differ. Silicon dioxide remains solid at moderately high temperatures, and attaining such temperatures is challenging. Therefore, it can be alloyed with other materials to produce glass melts in different states, which help shape operations and effective deformation.
These materials are known as fluxes. Numerous tightly bound metals, metalloids, and other substances create these fluxes. They can be limestone, feldspar, soda ash, boric acid, lead chemicals, or barium compounds. These chemicals help the glass's melting process, increase its chemical durability and mechanical strength, give it a better shade, and provide it with distinct luster and stability.
Once the raw material is selected, batching defines how glass manufactured. It is where different materials are proportioned and combined in a measured way to meet the standard and quality of the product. They can combine based on the outcome required like:
These raw materials are combined in a mixer to the appropriate standards to pave the way for other glass production procedures, such as melting and refining.
In this phase of the glass production process, the raw materials are blended in the proper ratio and poured into a furnace. The furnace, heated to around 1700°C (3090°F), melts the mixtures into molten glass. This melting phase is probably the most critical stage of the glass-making process because the mixture must be thoroughly homogenized, leaving no traces of impurities. Another aspect that needs to be looked after is "Bubbles" to ensure homogeneous mixtures and high-quality glass.
The glass industry has faced specific challenges, including energy-efficient melting and finding new ways to reduce its environmental impact. Technological advancements in the glass production industry, such as oxygen-fuel burners and electric melting furnaces, have greatly enhanced glass manufacturing techniques.
This is the turning point for the molten glass, where the glass is converted into a solid to shape it as per the required functions. This process has to be effected within a specific temperature range to transform it from a viscous liquid to a plastic and then to an ultra-glassy state. It is worth noting that the method used to form the glass depends on the end use of the glass product. Each method is characterized by unique strengths that make it ideal for particular forms of glass products. Let's delve into the four primary methods used in glass production:
Float Glass Process: The Float glass process is the premier method for producing flat glass, widely used for windows, mirrors, and architectural purposes. Here, the molten glass is floated on a layer of molten tin. Because of the difference in the densities of the glass and tin, the glass spreads evenly on the tin, preparing a flatbed. The controlled cooling gives the glass the proper thickness, making it high-quality.
Blowing Process: Blowing is an exemplary work of art and dexterity that goes into glass production. This process is carried out after drawing a gob of molten glass on one end of a hollow blowpipe. Then, the air is blown through the pipe, creating the final form of the bubble by skilfully twisting and moving it in various directions with delicate precision. Glass blowing demands a lot of experience since the glass always needs to be at a specific temperature to be molded.
Pressing: Pressing manufactures dense products such as tableware, lenses, and some classes of optical glass. This method involves carefully pouring the molten glass into a mold, and the quantity of the material is accurately calculated. A plunger then forces the glass into the mold cavity to the required shape of the produced product. Pressure must be appropriate for items that need complex patterns or unique optical characteristics.
Drawing: It is used to manufacture glass fibers, tubes, and all other elongated glass parts. In this process, glass is passed through small dies or nozzles to form thin, continuous strands of glass. The drawn glass is quickly cooled for fiber manufacture to produce tiny filaments, which may be wound onto drums for further processing. This method is instrumental in producing fiberglass, which is widely employed in insulation, composites, and optical fibers.
Thermal stress can impair the mechanical and thermal resistance of glass. This results in the glass mat likely breaking during chilling, storage, transportation, and usage. To avoid this, glass goods must be annealed once they are formed. Annealing is a process of heat treatment in which the glass is heated to a given temperature range and then held or cooled slowly for a considerable amount of time. This process assists in eliminating the need to reheat the glass in the event its thermal stress levels are high or lowering them to allow tolerance to improve the quality of the glass.
Thermal stress can impair the mechanical and thermal resistance of glass. This results in the glass mat likely breaking during chilling, storage, transportation, and usage. To avoid this, glass goods must be annealed once they are formed. Annealing is a process of heat treatment in which the glass is heated to a given temperature range and then held or cooled slowly for a considerable amount of time. This process assists in eliminating the need to reheat the glass in the event its thermal stress levels are high or lowering them to allow tolerance to improve the quality of the glass.
Cutting: In cutting glass, one has to scribe a particular line on the glass in a controlled manner using a diamond-tipped or carbide wheel tool. This scoreline is used to break the glass to create exact slits. This method is applied in situations where a large sheet of glass needs to be divided into other smaller pieces or shapes depending on the requirements of a particular design or use.
Polishing: Polishing smoothes all the roughness and irregularities on the edges and flat surfaces of the cut glass. This is the step in which the edges are ground using coarser and progressively finer grits to obtain a high polish.
Coating: Coating processes improve the properties of glass for specific uses. Chemical Vapor Deposition(CVD) or Physical Vapor Deposition(PVD) makes film uniform and temperate, improving the glass's functionality and look.
Tempering: Tempering enhances the mechanical properties of glass. Tempered glass is about four to five times stronger than ordinary glass that has not been treated. When tempered glass cracks, it does not splinter into sharp edges. This property makes tempered glass worthwhile, providing safe use.
Closely monitoring the quality of the final product, accompanied by the adherence of the glass to specific requirements that are expected, plays a vital role in the glass making process. Some of the measures taken for the glass quality inspection include coatings checks, verifying the clarity of the two pieces of glass, which may affect the appearance of the glass, and checking for bubbles or inclusions, which may weaken the structure. Separate checks aim to confirm that the thickness, length, and width of the glass produced are as required. Furthermore, process techniques such as laser scanning and automated defect detection systems are commonly used to increase the effectiveness of quality assurance and ensure that the best quality glasses are produced.
The technique of glass production is a unique example of how people transform natural resources into materials that define our world. Every operation has a role in making quality glass products, and all of them are significant, helping each other out. Subsequently, as technology progresses and the effects of climate change are realized further, the future of glass manufacturing is set to open further horizons of innovation. FEEMIO – a brand that manufactures and sells molded glass bottles and jars, is committed to delivering high-quality products and services, which entails sustainability initiatives and satisfying clients' needs and preferences. FEEMIO team encourages cooperation or consultations regarding the glass manufacturing process and the products it yields. Contact us.
