We invite you on an excursion to one of the largest enterprises located beyond the Urals - the Novosibirsk enterprise OJSC Ekran Plant, which produces glass products. The rather strange name is explained by the fact that before its repurposing the plant produced television equipment. 
And we will talk about how glass bottles are born and more. 
It produces clear glass bottles with a capacity of 0.25 to 1 liter for carbonated drinks, beer and liquor, brown glass bottles, as well as jars with a capacity of 0.25 to 3 liters for sauces, juices and other canned products.
Glass furnace.
Being the largest manufacturer of glass containers in the territory from the Urals to Far East, the plant produces 620 million units of glass containers per year (almost 1.7 million units per day).
The production of glass containers consists of two workshops (for the production of colorless bottles and brown bottles).
These bottles are ready, but have not yet passed the quality check.
The process of producing glass containers consists of several successive stages: the initial raw materials are prepared, the charge is compiled, then the glass melt is melted, the products that are ready for use are formed and annealed. last stage undergo quality control and are packaged.
The initial raw materials are cleaned of unwanted impurities, after which they are prepared for further processing and use. A charge is a dry mixture of materials fed into a furnace to produce glass melt. To obtain a homogeneous mass, during the process of preparing the charge, the components are weighed in certain proportions and mixed.
This is a glass furnace: batch and cullet are fed into it. Such a furnace produces almost 180 tons of glass melt per day.
Melting glass melt is the most difficult operation in the production of glass containers. It is carried out in continuous bath furnaces, which are pools made of refractory materials.
When the charge is heated to a temperature of 1100-1150ºС, silicates are formed first in solid form, and then in the melt. A further increase in temperature in the melt leads to complete dissolution of the most refractory components, resulting in the formation of glass melt, which is heterogeneous in composition and saturated with gas bubbles. To lighten it, the temperature is increased to 1500-1600ºС.
Glass melt leaving the glass furnace.
The transparency and color of the bottles depend on the addition (or absence) of dyes and opacifiers to the mixture. Thanks to mufflers (phosphorus, fluorine compounds, etc.), the glass becomes opaque. Different color glass mass is achieved using various connections: blue- these are cobalt compounds, green– chromium, purple – manganese, blue-green and brown – iron and others.
This process smells quite unpleasant.
At the end of glass melting, the glass melt is cooled to the temperature required to obtain the viscosity required for blowing glass forms.
The glass melt is fed to the glass lines. At the bottom of the photo you can see two bright drops of glass melt falling - they will become bottles in the future.
And here is the process of creating droplets of glass melt.
The finished glass melt is fed to molding machines that mold the products.
A 10-section line that produces bottles from brown glass melt.
After molding, glass products undergo additional heat treatment (annealing) in direct heating furnaces. Thanks to annealing, the internal residual stress in glass containers is removed, ensuring the product’s safety during further processing and subsequent use.
At the entrance to the annealing furnace, the products have a temperature of about 400-500 degrees Celsius, and at the exit - about 50-80.
Glass containers after annealing.
Bottles are sprayed with a special solution that protects them from abrasions and scratches during transportation.
The products still need to undergo quality control.
This workshop is equipped with modern inspection machines that scan every glass bottle every second for compliance with established requirements.
The products are already packaged.
In another workshop, clear bottles and jars are produced, and quality control is carried out manually.
The production of glass bottles and jars is a process that requires maximum dedication. If even small details of container manufacturing are not observed, then the end result can be 20 liter bottles with walls of unequal thickness. The problem may also be the fragility of the material or the uneven shape of the container. There can be quite a lot of nuances, so it’s better to trust the “GLAVSTEKLOTARA” Trading House.
Wide range of glass bottles from Glavsteklotara
The products presented in our catalog meet all quality standards and are distinguished by high performance characteristics. Our products not only have good tightness, but also have other, no less beneficial properties. You can store juices, water, and various drinks in such containers. They are great for cooking homemade wine and moonshine. Separately, it is worth noting the container, which holds up to 0.5 liters. It can be considered universal, since in the mass bottling of drinks in such containers it is considered the most profitable from an economic point of view.
Our company has also established the production of bottles that are used for champagne. This is a special container that has dark glass to prevent fermentation of the drink, has fairly thick walls and a special elongated neck. Only in such conditions can champagne be stored for as long as required by GOST or TU. It is our price that is distinguished by an acceptable range for large productions, and for small enterprises that are just starting to produce their own sparkling wines.
It is important to understand that the cost of producing glass bottles directly affects how much the finished product will ultimately be valued at. We were able to optimize the process so much that thanks to automated lines you receive exactly the containers that are needed for specific purposes.
The company "Trading House "GLAVSTEKLOTARA" presents a wide range of glass products, as well as various components intended for high-quality storage and transportation of products. So, you can purchase from us such a type of product as a yoke stopper. If you want to learn more about cooperation with us, call the numbers listed on the website.
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Plastic containers for drinks in lately is in great demand. You can pour juices into it, mineral waters, carbonated drinks, beer, and other alcoholic and non-alcoholic drinks. Therefore, organizing a manufacturing business plastic bottles considered quite profitable. This will require an automated bottle production line, a workshop where it will be located, service personnel. For businessmen who produce a variety of drinks, it makes sense to purchase equipment for making containers and carry out this process themselves. Thanks to this, you can save up to 25% on plastic container costs.
Features of PET bottles
Plastic bottles began to be produced in the 70s of the last century; DuPont was the first to produce this type of container. At that time, this became a revolutionary invention, and the bottles themselves seriously competed with glass bottles. Today, glass bottles are rapidly being replaced by plastic ones due to a number of reasons:
But plastic also has its disadvantages:
- it allows ultraviolet radiation and oxygen to pass through, as a result of which the contents lose their characteristics and the shelf life is reduced;
- it releases carbon dioxide, which is especially important for carbonated drinks, kvass and beer.
Necessary raw materials for production
PolyethylThe main source material is polyethylene terephthalate - PET, thermoplastic. When exposed to high temperatures, plastic molecules polymerize - they combine and form larger compounds, which increases the volume of raw materials. Dyes are used to give the product the desired shade. During the production process, some products are rejected, in this case there will be a high percentage of rejects - up to 25%, it can be processed using it as a raw material. Thus, waste-free production is obtained.
Room
Workshop for the production of plastic containers To accommodate a line for the production of PET bottles, you will need a room with an area of more than 40 m2, a ceiling height of 4 m, during its preparation fire safety requirements must be met, since furnaces are used, the temperature of which during operation rises to 200 o C. Therefore, it is advisable to line the walls and floor with tiles or non-combustible materials, concrete. The workshop must have three-phase sockets with a voltage of 380V. All utilities are required - water supply and sewerage, air conditioning, ventilation. Separate ones will be needed warehouses, for storing raw materials and finished products. To organize a small enterprise focused only on the production of plastic containers, it is not at all necessary to purchase real estate; it will be much more economical to rent production space. Production equipment
There are two types of plastic bottle production lines:
- single-phase, when the process of making the preform and blowing the container occurs in one place, while the preform will maintain a high temperature;
- two-phase, when preforms are made on one machine, and then the line operator manually transfers and loads them into a blow molding machine. At the same time, the preforms cool down, and the blowing apparatus needs to heat them up again.
Components of the automated line:
- PET platform;
- bake;
- automatic bottle blowing machine.
The PET platform is designed for the formation of preforms by heat treatment of polyethylene terephthalate granules. Specifications:
- number of nests – 6;
- mold thickness – up to 240 mm;
- power supply – 380 V;
- power – 73 kW;
- dimensions – 2000*950*2480 mm;
- weight – 250 kg.
A conveyor-type oven, as part of a PET bottle production line, is designed for heating preforms. Uniform heating is ensured by eight active zones, due to which in the future the product will be blown into the correct shape and the percentage of defects will be reduced. Specifications:
- productivity – up to 1200 pcs/h;
- power – 8 kW;
- voltage – 380 V;
- dimensions – 1270*520*1220 mm;
- weight – 260 kg.
There are two types of automatic blow molding machine:
- for the manufacture of containers with a volume of 0.2 to 5 liters;
- for the manufacture of containers with volumes from 5 to 19 liters.
Thanks to the high speed of hot air supply, the blowing process is carried out very quickly, and the bottle is of the correct shape. Specifications:
- power – 5.5 kW;
- productivity – 700 pcs/h;
- blowing pressure – 14 atm;
- dimensions – 1800*500*1000 mm;
- weight – 250 kg.
The cost of a line for the production of bottles of this configuration will be 800 thousand rubles.
Manufacturing technology
Two-phase blowing line At the first stage production cycle it is necessary to form preforms - blanks. First, the raw material, polyethylene terephthalate, is heated; it comes in the form of granules, which, under the influence of high temperature, increase in volume and combine into a homogeneous mass. Then the hot mass is poured into metal molds, which can be standard, the most common, or can be made according to an individual project, then the finished product will have an original design. The filling process must be carried out as quickly as possible so that the molten mass is evenly distributed throughout the mold. If this stage is performed correctly, the finished product will not be deformed.
In the next step, the preforms are cooled using liquid carbon dioxide, or water cooling is also possible. Next, the blanks are sent to a blow molding machine, where the bottle formation process is carried out under high pressure, up to 30 atmospheres. Thanks to high pressure, the entire process requires a minimum of time, and the product is obtained in the desired shape and size.
The next stage is quality control; all products with visible deformations are subject to removal and further processing. The bottle production line can be supplemented with an automatic shredder for recyclable materials and defective products. Thus, making production waste-free and saving on raw materials.
Business Features
Organizing your own enterprise for the production of PET containers will not require significant capital investments. To start you will need no more than 1.5 million rubles.
Heated preform under pressure takes any shape During the production process, the main cost item will be wages to the staff. Three workers will be required, a loader, a driver, a manager, an accountant and a supervisor; it is possible to combine management positions into one. Another significant expense item will be utility bills - during production goes big energy consumption, since all equipment has quite a large power. There will also be a significant consumption of water for cooling preforms and finished products.
Despite high competition, this type of business is considered highly profitable; the cost of a bottle production line can pay off within six months of equipment operation, provided that the finished product is fully sold. This can be achieved by concluding agreements with manufacturers of drinks, juices, and draft beer.
Video: PET bottle blowing machine