Report Vadim Mahorova
It often happens when I go to the factory, have no idea what is waiting for me there. This time it was the same thing, I had to visit the largest east of the Urals production of glass and I imagined a huge production areas, but in reality it was different.
1. Glass line.
The history of the plant began after World War II — it was then the Soviet Union began to think about building a base for the production of electronic devices for radar and television. In 1948 it was decided to build the plant, and in 1954 he began his work as an enterprise electronic industry for the production of electro-optical devices, cathode-ray tubes for oscilloscopes and television picture tubes for a complete set of plants. For decades, the plant regularly exporting its products to the needs of the partner companies, but with the cessation of mass production in the Russian television technology in 1994, he has been redeveloped to produce glass containers.
Today JSC "Plant" Screen "- a company is a leading manufacturer of glass containers in the territory from the Urals to the Far East. The assortment of the factory is a bottle of colorless glass with capacity of 0.25 liters to 1 liter for bottling of alcoholic beverages, beer and soft drinks, cans of juice, sauces and other canned products with capacities from 0.25 to 3 liters bottles of brown glass.
3. Steklovarnaya oven.
Speaking of large-scale production of glass in the Urals, I meant that production capacity — 620 million units. glass bottles a year. If we divide by 365, we get about 1.7 million units. day. One of Novosibirsk as many bottles would be plenty, glass demand among enterprises of the Siberian and Far Eastern Federal Districts of the Russian Federation, as well as Kazakhstan and Kyrgyzstan.
But the biggest manufacture in this case — it's just two shops (production of colorless bottle and brown).
4. Prepared, but not yet passed quality control bottle.
Technology of production of glass consists of the following sequential processes:
— preparation of raw materials,
— preparation charge,
— cooking glass,
— forming and annealing products
— quality control and packaging.
Preparation of raw material is cleaned from the source of raw materials and undesirable impurities preparation for further processing and use. This should be separate storage of raw materials and the supply of raw materials into the receiving hopper.
The charge — is a dry mixture of materials that are fed into the furnace to produce molten glass. Overview In the process of charge is determined by weighing the components in proportions and mixing to obtain a homogeneous mass. To prepare the blend, the following raw materials: quartz sand, dolomite powder, glass, chalk Technology, alumina, soda ash, sodium sulphate, obestsvechivateli, colorants, etc.
5. Steklovarnaya furnace in which the fed batch and cullet. Performance of such a furnace of 180 tons of glass per day.
Cooking glass — the most difficult operation of all glass production, is produced in a continuous tank furnaces, which are pools built of fire-resistant materials.
Upon heating of the charge to 1100 … 1150 ° C the formation of silicate initially in solid form and then melt. With further increase of temperature in this melt completely dissolve the most refractory components — glass melt is formed. This molten glass is saturated with gas bubbles and uniform in composition. For clarification and homogenization of molten glass increases its temperature up to 1500 … 1600 ° C. The melt viscosity is reduced and thus facilitating removal of gas bubbles and obtaining a homogeneous melt.
6. Glass at the furnace exit.
The color and transparency of the bottle, is determined by adding (or absence) of dyes and silencing the charge. Muffler (fluorine compounds, phosphorus, etc.) make the glass opaque. By the dyes are compounds of cobalt (blue), chromium (green), manganese (purple), iron (brown and blue-green tones), and other
7. The process is quite malodorous.
Glass ends of glass cooled to a temperature at which it acquires the viscosity required to produce blow glassware.
8. Submission of glass on glass line. At the bottom of the frame shows two bright drops falling glass — bottles are the future.
9. The process of creating gob.
11. Ready is fed to the molten glass forming machines, which is forming products with use of appropriate equipment.
13. Desyatisektsionnaya line, which produces a brown glass bottle.
After completing the molding process, glassware undergo additional heat treatment (annealing) in the direct heating furnace. Annealing is required to remove internal residual stress in glass, which makes the preservation of the product during subsequent processing and use.
Low product inlet annealing furnace: approx 400 ° C — 500 ° C.
The temperature at the exit of products: approx 50 ° C — 80 ° C.
16. Spraying bottle with a special solution that prevents scratches and scuffs on the bottles in transit.
17. Products are ready, you just go through quality control.
18. This complex is equipped with modern glass inspection machines that every second scan parameters for each glass bottles to meet the requirements of the buyer.
19. Packaged products.
I showed the process of manufacturing the glass bottles at the new complex. There is another shop where they make clear bottles and jars, where quality control is done manually. The first 4 and the following 7 pictures taken there.
20. In the production of both workshops is very noisy. We have to go to the ear plugs or noise reducing headphones.
21. The process of creating a two-liter jars.
24. Vodka bottles after annealing.
25. Quality control.
26. Finished products.
I advise you to watch a short video sequence, shot me in the workplace.