Technology

A solid know-how accompanies innovative technologies

Verallia produces by summarising years of experience and a continuous definition of new technologies that allow the company to obtain products with high technical contents. In this way, Verallia bottles and glass jars fully meet all the functions requested by the users.

 

Production process

Sand, fire and air: the ancient magic of glass

Hollow glass is obtained through an industrial process divided into three stages: melting, forming and annealing.

The melting starts by collecting in silos sand, sodium carbonate, carbonate of lime and colouring, natural raw materials that batched, mixed and placed into the melting furnace at a temperature of 1600°, combine until they reach the liquid state. In this phase, the cullet replacing much of the raw materials is increasingly present.

The melted liquid out of the furnace is ready for the forming phase. By passing through thermal conditioning channels, it reaches the right viscosity and is cut into incandescent drops that fall into the mould of the forming machine through a vertically guided drop. The container takes shape in the mould with the traditional “blow-blow” process or with the innovative “press-blow” process. 

The container now moves to the annealing phase. A procedure that eliminates the tensions of glass through a preliminary heating and subsequent gradual cooling until it reaches room temperature. A method that eliminates the tensions generated by the forming and causes the glass to cool without thermal imbalances that might compromise the mechanical strength of the container.

At this point, the containers are ready for quality control. All the characteristics of the products are tested: size, shape, thickness, calibration of mouths, integrity, and strength. Containers considered unfit are expelled from the packaging line to be remelted in the same production process. The technological innovation of Verallia enables the computerised management and monitoring throughout the production cycle, ensures control over statistical basis, in order to obtain the quality of the finished product meeting the functional and aesthetic requirements of bottlers, distribution and consumer.

Blown/blown

After the cut, the drop is guided, with appropriate channels, to the individual sections.

Each section consists of a blocking die and a finisher arranged in-line. The former receives the drop upside down and is surmounted by a guide ring.

The blowing occurs through the head spindle; the blocking die opens and the outline, supported by the die of the mouth, is transferred, by rotation in the open air in the finishing die where the final blowing takes place.

Blown/pressed

It differs from the blow-blow process only for the forming of the outline that takes place by pressing. Some machines are equipped to work with both processes. The pressure-blow process is particularly suitable for producing wide-mouthed containers (jars) and, thanks to new technological developments, it is adaptable to the most difficult narrow-neck containers.  Innovation that allows to create lighter containers with a better mechanical performance.

Did you know that…

  • Glass was created by chance. It is claimed that some Phoenicians who lighted a campfire and used nitrate blocks to support the pots discovered it accidentally around 5,000 BC near the Belus River in Syria. The nitrate blocks melted because of the heat of the fire and formed a transparent liquid with the sand of the beach.
  • Glass is a material that decomposes slowly, but it is the only one to be compatible with the environment.
  • In 2012, the amount of recycled glass packaging waste reached 1,568,000 tons. The recycling rate is now 70.9%.
  • Recycling one ton of glass saves about 1.2 tons of raw materials. 
  • With 1 kg of cullet recovered with separate collection, we obtain 1 Kg of new glass containers recycled endless times without any loss.
  • Recycling one ton of glass saves about 1.2 tons of raw materials.