A fascinating journey is involved in transforming sand grains during glass bottle manufacturing. Safe and efficient glass bottles are essential for specialists, especially those wanting long-lasting, sterile packaging.
Materials required for glass bottle manufacturing
Glass manufacturing for pharmaceutical packaging goes through a certain process. The steps involve:
The first step of glass bottle manufacturing is putting together all of the raw materials. Typically, soda-lime silicate glass is used for the industry. It is sterile, efficient, and durable, which is ideal for storing medications and drugs.
The basic ingredients of this glass include sand, limestone, soda, and recycled cullet. These are all found from natural sources and then used to manufacture glass bottles.
The collection of all four raw materials to begin the production process is referred to as a batch. Each and every batch will include natural raw materials, to ensure that the glass bottles are 100% eco-friendly.
100% eco-friendly.
Sand
Limestone
Soda
Recycled Cullet
Did you know that according to Statista, glass bottle production is forecast to reach 916 billion units by 2028?
Melting and shaping the glass
The next stage of glass bottle manufacturing is melting and shaping the glass. The raw materials are put all together in a furnace. This furnace will reach a maximum temperature of 1600 degrees Celsius. A high-quality furnace can take around two days to melt all materials.
The materials need to be melted effectively in order for them to be able to mould into glass bottles. The liquid materials are then directed deeper into the feeder and from there, the forming of the glass bottles can begin.
Small glass parts, known as glass gobs, are cut away where possible before the bottle materials are put into the moulds. This is so that the glass bottle can be durable and perfected throughout the moulding stage.
The glass bottles are created through compressed air and cast iron moulds pressing the liquidised raw materials together. The air and moulds are within an electrical machine, which can perform an impressive conversion from liquid materials to solid materials. This process can take a matter of seconds.
Manufacturing glass bottles: annealing and inspecting
The third step of glass bottle manufacturing is annealing and inspecting. This is where the moulded bottle is taken throughout hot and cold temperatures, which further enhances the solidifying process.
Annealing refers to the cooling process. Annealing is achieved in a Lehr, which involves a hot furnace reheating the bottle before cooling it down to room temperature. The Lehr moves the glass bottle in a forward direction and when the bottle approaches the end of its journeys in the Lehr, an outer coating is added to act as protection.
The second stage of this step is inspection. Once the bottles come out of the Lehr, they will go through close examination. This inspection is to ensure that all containers have no defects. If they do show signs of defects, then they will be rectified if possible. Or, the defective bottles that will be of no use will be discarded and/or used for other purposes.
Pharmaceutical glass type 1
Glass type 1 glass is most common in tubular format but is also manufactured in moulded bottles and vials. It offers great chemical resistance so that the ingredients inside can be safe and not vulnerable to external conditions. For example, it is thermal shock and heat-resistant, which makes it safe no matter what environment it is in. It can endure both hot and cold temperatures, which can sometimes be necessary for the transportation of medications.
There are other types of glass used in pharmaceutical packaging: take a look at our blog on the type I, type II, and type III glass here.
Other benefits of pharmaceutical glass type 1 bottles include:
- Chemically inert. Glass type 1 is also chemically inert so that it will not be reactive with other substances. This is important so that the ingredients inside will not be affected should the bottle come into contact with an active ingredient that could cause the ingredients to change in efficacy.
- Durable. The glass is extremely durable, which is crucial for the pharmaceutical industry. Not only is it durable against temperatures, but it is likely to last much longer when it is in transport or being handled.
- It can contain strong ingredients. Glass type 1 is also highly resistant to strong ingredients, such as acids and alkalis. This means that all types of medications and substances can be stored within them and the ingredients will not react with the glass.
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