Why The Glass Bottle Production Line Cannot Be Stopped During The Production Process

The operation of the glass bottle production line is a complex process that demands uninterrupted operation for various reasons, from preserving temperature control to avoiding detrimental equipment damage. The continuous nature of glass production ensures consistent quality and maximizes efficiency. Here, we delve into the significance of continuous production and the potential consequences of halting the production line.

A brief overview of the glass bottle production process

The glass bottle production process involves melting raw materials, such as silica, soda ash, and limestone, in a furnace, forming molten glass that is then shaped, blown, and cooled to create the final glass bottles.

The significance of continuous production in industry

Continuous production in industry is significant as it ensures consistent quality, maximizes efficiency, minimizes waste, and meets customer demands, ultimately leading to cost-effectiveness and sustained competitiveness.

Why the glass bottle production line cannot be shut down

Affects temperature control

The critical role of temperature control in glass production

Temperature control is a cornerstone of the glass production process, pivotal to ensuring the quality and uniformity of the end product. Its significance can be distilled into three key facets.

Firstly, maintaining precise temperature control is paramount for achieving uniform heating of the raw materials within the glass furnace. This uniformity underpins the even melting of the materials, yielding glass with consistent attributes, encompassing clarity, thickness, and structural integrity.

Secondly, temperature control is instrumental in managing the viscosity of molten glass. Diverse glass formulations necessitate specific viscosities to take on various shapes and forms. Temperature regulation ensures that the glass maintains the requisite fluidity, enabling it to be molded and shaped as per the intended design.

Lastly, temperature control serves as a bulwark against thermal shock, a phenomenon to which glass is acutely susceptible. Preventing sudden temperature fluctuations, temperature control mitigates the risk of thermal shock during the cooling and shaping phases, thereby averting undesirable cracking or fracturing of the glass product.

The impact of stopping the production line on temperature management

The interruption in the production line causes temperature variations that can result in disparities in the properties of the molten glass, potentially leading to defects or irregularities in the glass products, thereby affecting their overall quality and marketability.

Additionally, halting the production line and subsequently restarting it imposes increased energy consumption as the equipment needs to be reheated, rendering the process less energy-efficient and potentially elevating operational expenses.

Furthermore, the frequent stops and starts subject the glass melting furnace and associated equipment to thermal stress, which, in turn, can lead to wear and tear, necessitating maintenance and potentially incurring substantial repair costs.

The most important is a drop in the temperature of the raw materials will cause liquid materials to solidify and potentially adhere to the equipment. This solidification process results in changes in the volume of liquid materials, posing a risk of damaging the machine's pipes and introducing undesired effects on the equipment. Removing solidified materials from the equipment demands significant human and material resources, sometimes proving challenging to achieve, ultimately leading to considerable equipment damage and a shortened machine lifespan.

Damage to the machine

The sudden halt of a glass bottle production line during production can result in damage to the production equipment for various reasons. One reason is thermal stress, given that glass production involves operating at high temperatures, and when the production line unexpectedly stops, the equipment cools down rapidly. This rapid cooling, in turn, subjects the machinery to cycles of heating and cooling, placing it under thermal stress that may cause components to expand and contract, ultimately leading to weakened structural integrity and potential damage.

Additionally, mechanical stress is another consequence, as the abrupt starts and stops generate mechanical stress on the production equipment. The sudden cessation and subsequent acceleration of machinery subject it to powerful forces, which can result in wear and tear on critical components, such as gears, bearings, and electrical systems, potentially causing damage.

Lastly, the third factor is material buildup, a common occurrence in glass production. Residues and material buildup accumulate on the equipment over time, and when the production line comes to a halt, these materials can harden or solidify on the equipment, obstructing smooth machinery operation and leading to potential damage when the line is restarted.

A case where the glass production line stopped working

Most glass production plants prepare for special circumstances, but the unexpected does happen. In December 2020, an unforeseen power outage struck the Takatsuki plant of Japanese glass substrate manufacturer NEG, causing a 5-hour interruption in their production line. This incident had significant repercussions as it resulted in damage to the glass melting furnace and feeding trough, necessitating a temporary shutdown of the production line, which was estimated to last for about four months.

During the power outage, the drop in temperature caused the glass to adhere to the feed trough, leading to damage to three furnace plants and five troughs. While NEG aimed to expedite the repair of two feeder troughs by January 2021, the restoration of the remaining three was expected to take until February or March. The outage particularly impacted the supply of glass substrates, notably for panels below the 8.5 generation.

How do we prevent the glass production line from stopping?

Preventing sudden stops in the glass production line involves 3 key strategies:

1. Regular Maintenance and Inspections

Regular maintenance and thorough inspections of the production line are essential. Scheduled maintenance checks can identify potential issues before they escalate into major problems, helping to keep the equipment in optimal condition. This proactive approach ensures that any worn-out or faulty components are replaced promptly, reducing the likelihood of unexpected stoppages.

2. Install Backup Power Sources

Installing backup power sources, such as generators or uninterruptible power supply (UPS) systems, can safeguard against power outages. In the event of an unexpected power disruption, these backup sources provide a reliable and uninterrupted power supply to keep the production line operational. This redundancy helps mitigate the risk of sudden stops due to electrical failures.

3. Train the Production Team

Providing comprehensive training to the production team is crucial for efficient operation and troubleshooting. Equipping them with the necessary skills to handle the equipment effectively and address common issues empowers them to respond swiftly in case of any potential disruptions. Additionally, well-trained personnel can implement immediate corrective actions, minimizing downtime and preventing sudden stops.