MBAA Rocky Mountain DistrictTechnical Summit June 25, 2010

Everything’s Better in GlassConnie Maxwell, Quality ManagerO-I Windsor, Colorado

Owens-Illinois, Inc. Global Glass Industry Update 2

Owens-Illinois, Inc.

• Founded 1903 in Toledo, Ohio

• Operating in 22 countries

78 glass factories

169 furnaces

446 machines

• 23,000 employees

Hot End, Windsor Plant, CO

O-I North America #1

O-I Europe #1

O-I Asia Pacific #1

O-I South America #1

O-I Global Glass Profile

•19 manufacturing plants• 6,000 employees• 1.2 million tons of recycled glass

•10 manufacturing plants• 3,500 employees• 0.6 million tons of recycled glass

•11 manufacturing plants• 4,600 employees• 0.4 million tons of recycled glass

•38 manufacturing plts• 8,500 employees• 3.0 million tons of recycled glass

O-I North America Facilities

1 Auburn, NY2 Crenshaw, PA3 Brockway, PA4 Toano, VA5 Danville, VA6 Winston-Salem, NC7 Atlanta, GA8 Zanesville, OH9 Lapel, IN10 Streator, IL11 Muskogee, OK12 Waco, TX13 Portland, OR14 Oakland, CA15 Tracy, CA16 Los Angeles17 Windsor, CO18 Brampton, Ontario19 Montreal, Quebec

13

16

1514

17

12

11

76

54

10

19

18

89

2, 31

Why Everything’s Better in Glass

• Infinitely recyclable with no loss of quality• No flavor or chemical transfer to contents

of container• Takes less energy to re-melt a glass

container than to melt the raw materials

The Glass Container FactoryHOT END

COLD END

Batch and Furnace

Forming

Surface Treatment

Selecting / Inspection Carton Assembly

Palletizing Shipping

Batch House

•Raw Material Unloading –Truck or Rail

•Storage –Individual Silos

•Batch weighing –± 0.1 % Accuracy

•Batch Mixing •Mixed Batch Transport

1) Raw Materials

70% Sand15% Soda Ash12% Limestone Plus 3% Colorants and Oxidizers

Batch composition:

2) CulletUp to 50% recycled glass from internal plant sourcesand recycling centers can be used. Cullet aids in fuel efficiency and melting in the furnace.

Exhaust Flue

Doghouse(Batch Delivery) Melter

Refiner

Throat End Wall

Ports (Fuel)

Ports (Fuel)

Exhaust Port

Alcove

Forehearth

Windsor PlantOxygen Fueled Furnace

Feeder

Forming Machine

Forming Machine

Melter Area

Glass Flow

Glass Flow

Batch Delivery

Entry into refiner / alcoveleading to forehearth

Furnace Interior

Glass FormationApproximate Temperatures (Degrees F.)

•Melting (Furnace) 2750 degrees•Conditioning (Forehearth) 2100 degrees.•Gob Formation / Forming 1700 degrees•After Formation (Softening Point) 1300 degrees•Lehr Entry (Annealing) 900 degrees

Batch and Furnace

After melting in the furnace, the glass flows into a forehearth where further conditioning takes place to prepare the glass

for the forming process.

Feeder

Forehearth

Feeder

Glass is formed into “Gobs” bya ceramic tube pushing the glass through orifices or openings at the base of the feeder.

The number of orifices is equal to the number of bottles produced on each section of the machine.

TUBE

A gob is a specific amount of molten glass that will be formed into a glass container.

FeederWhat is a gob?

Diameters 3/8” to 4”

Lengths ½” to 6”

Forming Operations

There are three phases to making a bottle once the gob leaves the feeder:

1. Delivery Equipment2. Blank Side of the Forming Machine3. Mold Side of the Forming Machine

Delivery Equipment

Scoop:Routes gob to section that is ready

Trough:Routes gob to proper deflector

Deflector:Provides control of path of falling gob for exact alignment in center of blank.

Gob delivered into the blank at 1300 ºF

Gob enters the delivery system at 1700 ºF

Forming Machine12 Section Quad

On the Windsor machines,12 Individual Sections produce 4 bottles at each section

There are 4 cavities in each section. Each cavity hasa unique number.

Forming• The gob is delivered into the blank mold side of the

machine or the rear of the machine and is formed into a parison.

• The parison will be formed by either the Press and Blow or the Blow and Blow process.

• During the forming cycle, lubrication is manually applied to the blank molds and blow molds.

Glasshouse Terms:• The “Parison” is sometimes called the “Blank”.• The technical name for the “Press and Blow”

operation is “NNPB” - Narrow Neck Press and Blow• Applying lubrication to the molds is called “doping”.

A parison is a specifically shaped formation of glass which will be blow up like a balloon in the blow mold to form the bottle.

A parison has the following features:

What is a Parison?

FinishHollow insideCooler skin or enamel on its

outer surface

Temperature of 1300 degrees F on its outer skin.

The same amount of glass as the container it will produce

Parisons are formed on the blank side of an I.S. machine from the gob

Parisons greatly differ in shape for each process and are a precise shape for each type of bottle

Parisons are created in three seconds for a typical 12 oz. container and are just barely able to hold their shape

Bottle Forming Cycle

Narrow Neck Press and Blow Process

1) Gob Delivery

2) Start Press

3) Press4) Plunger

Down

5) Parison Reheat

6) Transfer to Blow Mold - Reheat

7) Parison Reheat and

Run

8) Final Blow and Vacuum

9) Bottle Takeout

10) Bottle Cooling

Parison Formation

Press and Blow Process

1. Gob entry

2. Start Press

3. Full Press

Parison Formation

Parison

Start transfer

Container Formation

Parison transfer to mold

Mold closes

Compressed air applied

Start pickup

Container Cooling

Pickup and placement on cooling pad

Cooling pad

Fan air applied

Container cooling and transfer to conveyor cooling pad

Cooling pad

Container transfer into annealing lehr

Tin spray coating application

Annealing lehr

• Total time required to produce a container varies, but beer and soda bottles take approximately 10 seconds.

• Each section can produce 1 to 4 bottles simultaneously.

• Machines may have anywhere from 4 to 16 sections.

• Depending on container size and shape, production speed may be as fast as 700 containers per minute.

Elements of an I.S. machine• Individual sections on the forming machine allows the

ability to take one or more sections out of production for repairs without removing the other sections from producing containers for the customer.

Between the discharge from the forming machine and entry into the lehr to begin the annealing process, the first part of a two part surface treatment is applied to the container.

Annealing & Surface Treatment

After discharge from the forming machine, the bottle must be annealed. Annealing is thecontrolled removal of heat from the glass container

1) Surface Treatment protects the outside of the glass container by applying a lubricious (slick) surface on the outside of the container.

2) Surface Treatment is applied in two stages:Hot End: Tin oxide is vaporized onto the container

after leaving the forming machine but prior to entering the lehr.

Cold End: Polyethylene is sprayed onto the bottlesat the lehr discharge.

Surface Treatment

Surface TreatmentHot End Application

Tin is vaporized onto the bottles.

Annealing Lehr Cross sectional view

Heating zones Cooling zones

Typical annealing temperature curve

800

400

0

ºF

1200

Annealing point

Annealing The Glass Container

What is the purpose of annealing?• To relieve internal stresses in

the glass that are a result of uneven cooling of glass container during the forming process.

• The outer surface of the container cools fast while inner surface cools slowly, creating the stresses.

Owens-Brockway Glass Containers Inc.Owens-Brockway Glass Containers Inc..

Owens-Illinois

Annealing Lehr Cross sectional view

Heating zones Cooling zones

Typical annealing temperature curve

800

400

0

ºF

1200Annealing point

How does the lehr anneal the glass?• Reheats the glass above 1050 ºF and holds

this temperature until temperatures inside and outside the container equalize. After that, it slowly cools the container back to room temperature.

How long does this preheating and slow cooling process take?

• Depends upon the size and shape of the container

• Times vary from 20 minutes to 90 minutes.

Annealing The Glass Container

Annealing

1) Samples are obtained immediately prior to the overhead sprays to check annealing in the “Polariscope”

2) Annealing is measured in gradients of 1-5 “discs.”

Lehr Discharge Polariscope

Annealing Strain Discs

Surface TreatmentCold End Application

Polyethylene is sprayed between the rows of bottles.

Backup sprays are also available should the first unit fail to applytreatment. A diffusion hood is used to keep spray from the bottom backup unit reaching the finish of the bottle.

Surface TreatmentSpray Head Location

Spray headmust be below finish.

Diffusion hood airflow must be sufficientto keep treatment off of the finish.

Lehr conveyor mat

InspectionAutomatic Bottle Inspection

•100 % of the glass containers are inspected in a series of sophisticated machines called FP’s or FPX’s. •Data is collected and monitored to allow ready access to trend analysis and defect detection.

Palletizing

Palletizing Methods

CARTONS

Various types of corrugated packages

BULK

Bottles are placed onto tier sheetsand stretch wrapped with plastic.

QUESTIONS?