MBAA Rocky Mountain District Technical Summit June 25, 2010 Everything’s Better in Glass Connie Maxwell, Quality Manager O-I Windsor, Colorado

Owens-Illinois, Inc. Founded 1903 in Toledo, Ohio 23,000 employees Operating in 22 countries 78 glass factories 169 furnaces 446 machines 23,000 employees Michael Owens was recently inducted into the National Inventors Hall of Fame for invention of automatic glass bottle blowing machine Helped to eliminate child labor in the U.S. Automatic bottle blowing machine began the first packaging revolution by standardizing sizes of containers Hot End, Windsor Plant, CO Owens-Illinois, Inc. Global Glass Industry Update 2

O-I Global Glass Profile O-I Europe #1 38 manufacturing plts 8,500 employees 3.0 million tons of recycled glass O-I North America #1 19 manufacturing plants 6,000 employees 1.2 million tons of recycled glass O-I Asia Pacific #1 10 manufacturing plants 3,500 employees 0.6 million tons of recycled glass Leading glass container manufacturer in 4 major regions of the world plus licensee network gives us unparalleled view of the industry Leading producer in 19 of 22 markets and sole manufacturer in 8 of these markets (Canada, Colombia, Ecuador, Peru, Estonia, Finland, Hungary, NZ) Managing our global footprint is a continuous effort to make sure we are properly allocating investment to match growth and ROIC Global scale makes it easier for us to adapt investment to changes in glass markets and consumer preferences O-I South America #1 11 manufacturing plants 4,600 employees 0.4 million tons of recycled glass

O-I North America Facilities 1 Auburn, NY 2 Crenshaw, PA 3 Brockway, PA 4 Toano, VA 5 Danville, VA 6 Winston-Salem, NC 7 Atlanta, GA 8 Zanesville, OH 9 Lapel, IN 10 Streator, IL 11 Muskogee, OK 12 Waco, TX 13 Portland, OR 14 Oakland, CA 15 Tracy, CA 16 Los Angeles 17 Windsor, CO 18 Brampton, Ontario 19 Montreal, Quebec 19 18 13 1 17 2, 3 14 10 8 15 4 11 9 5 16 6 7 12

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 Factory HOT END Batch and Furnace Forming Surface Treatment COLD END Selecting / Inspection Carton Assembly Note that plant is often referred to as the “Hot End” and the “Cold End” and mention why. NOTE: First Click brings presents slide, second click will automatically label various departments in the plant Palletizing Shipping

Batch House Raw Material Unloading Storage Batch weighing Batch Mixing Truck or Rail Storage Individual Silos Batch weighing ± 0.1 % Accuracy Batch Mixing Mixed Batch Transport (1) The typical glass container plant batch house consists of unloading, storage, batch weighing, batch mixing, and mixed batch transport to the furnaces. (2) The raw materials are delivered to the unloading area either by truck or rail. The unloader visually inspects the material, performs a screen test for oversize, and collects a small sample which will be retained until the material is used. (3) The vehicle is then placed over the unloading pit and opened. The material is transported from the pit to the elevator by a conveyor. The elevator then takes the material to the top of the batch house for storage. Each material must be placed in a separate storage silo. Thus there is a distribution mechanism to direct each material to the proper silo. The distributor is set either manually or by the unloading program in the batch house computer. When a batch is prepared the materials are weighed out in the proper proportions, either by individual or cumulative weighing scales. This slide shows individual scales for each material. The scales must be accurate to +/- 0.1% of their capacity and the accuracy is checked on a regular, frequent basis. In most batch houses the scales are controlled by the batch house computer. After weighing, the scales discharge the materials onto a gathering conveyor, which carries them to the mixed batch elevator where they are taken back to the top of the batch house. The batch is discharged into a surge bin above the mixer. The surge bin serves two purposes; it allows the scales to weigh another batch while the mixer is in use, and it allows us to weigh the total batch as a final check to insure that all materials have been weighed properly. The materials are mixed from 1 to 3 minutes in the pan mixer. In some plants a small amount of water is added to the batch in the mixer for dust control and to prevent segregation, or demixing, of the batch in subsequent handling. After mixing the batch is transported to the furnace charging floor for melting. Two types of transport systems are used, either belt conveyor or monorail trains. The slide shows a monorail train system.

2) Cullet Batch composition: 1) Raw Materials 70% Sand 15% Soda Ash 12% Limestone Plus 3% Colorants and Oxidizers 2) Cullet Discuss the slide. Container glass ware made by Windsor is a different composition from window glass, laboratory glassware, and drinking glasses. Discuss the role of cullet. Up to 50% recycled glass from internal plant sources and recycling centers can be used. Cullet aids in fuel efficiency and melting in the furnace.

Windsor Plant Oxygen Fueled Furnace Forming Machine Exhaust Flue Refiner Exhaust Port Ports (Fuel) Doghouse (Batch Delivery) Alcove Melter Ports (Fuel) Discuss the various parts of the furnace. BACKGROUND INFORMATION: The major differences between this and traditional furnaces are: No Checkers / Regenerators Fuel ports consist of two jets – oxygen/gas and just gas Refiner now extends from the furnace into the chambers leading to the alcove and forehearth. The alcove is not in the main furnace. Forehearth Throat End Wall Feeder Forming Machine

Entry into refiner / alcove Furnace Interior Batch Delivery Melter Area Glass Flow Entry into refiner / alcove leading to forehearth Glass Flow

Glass Formation Approximate 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 Discuss the slide.

Batch and Furnace Feeder Forehearth First Click shows forehearth, second click shows arrow pointing to feeder. Forehearth 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 Glass is formed into “Gobs” by a 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 Discuss the slide.

Feeder What is a gob? Diameters 3/8” to 4” Lengths ½” to 6” Each mouse click displays different parts for the explanation of the gob. What is a gob? Answer to “What is a gob?” Gob appears. Diameter of about 3/8” to 4” Length of ½ “ to 6”. SLIDE COMPLETE A gob is a specific amount of molten glass that will be formed into a glass container.

Forming Operations There are three phases to making a bottle once the gob leaves the feeder: Delivery Equipment Blank Side of the Forming Machine Mold Side of the Forming Machine This is an introductory slide to the forming process.. A detailed slide follows this one

Gob enters the delivery Delivery Equipment Gob enters the delivery system at 1700 ºF 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. Each mouse click will advance the gob as follows: Title and gob entering are already present on the slide. Scoop Deflector Gob enters blank. Gob delivered into the blank at 1300 ºF

Forming Machine 12 Section Quad On the Windsor machines, Discuss the slide and attributes of the machine such as state of the art, one of the largest machines in the world. Do not tell how bottles are made as future slides will guide you through the process. On the Windsor machines, 12 Individual Sections produce 4 bottles at each section There are 4 cavities in each section. Each cavity has a 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”. Discuss the slide.

A parison has the following features: What is a Parison? 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: Finish Hollow inside Cooler skin or enamel on its outer surface Each mouse click adds a different bullet as follows: 0) Question is already on the slide. Answer to the above question. Introductory statement noting 6 characteristics of the parison. Each click then displays a different characteristic. 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 HIDE THIS SLIDE WHEN PRINTING STUDENTS AND INSTRUCTORS BOOK. The same picture has been developed in slide # 17 for book printing. Each mouse click adds a different bullet or picture. Discuss what is on the screen.

Parisons greatly differ in shape for each process and are a precise shape for each type of bottle HIDE THIS SLIDE WHEN PRINTING STUDENTS AND INSTRUCTORS BOOK. The same picture has been developed in slide # 17 for book printing. Each mouse click adds a different bullet or picture. Discuss what is on the screen. Parisons are created in three seconds for a typical 12 oz. container and are just barely able to hold their shape

Narrow Neck Press and Blow Process Bottle Forming Cycle Narrow Neck Press and Blow Process 4) Plunger Down 1) Gob Delivery 2) Start Press 3) Press 5) Parison Reheat 6) Transfer to Blow Mold - Reheat Summary Slide 7) Parison Reheat and Run 9) Bottle Takeout 10) Bottle Cooling 8) Final Blow and Vacuum

Parison Formation Press and Blow Process Gob entry Start Press Full Press Each mouse click adds a different bullet or picture.

Parison Formation Start transfer Parison HIDE FOR WORKBOOK

Parison transfer to mold Container Formation Parison transfer to mold Compressed air applied Start pickup Each mouse click adds a different bullet or picture. HIDE FOR WORKBOOK Mold closes

Pickup and placement on cooling pad Container Cooling Pickup and placement on cooling pad Cooling pad Fan air applied Each mouse click adds a different bullet or picture. HIDE FOR WORKBOOK

Container cooling and transfer to conveyor cooling pad Discuss the slide. Note that the “cooling pad” is also referred to as the “dead plate”

Container transfer into annealing lehr Tin spray coating application There is no curve chain in Windsor. Ware will be directly loaded into machine.

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. 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. Each mouse click will produce a different bullet

Annealing & Surface Treatment 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. After discharge from the forming machine, the bottle must be annealed. Annealing is the controlled removal of heat from the glass container Click mouse to add 1 more bullet point

Surface Treatment 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 bottles at the lehr discharge. Discuss the slide.

Surface Treatment Hot End Application Tin is vaporized onto the bottles.

Annealing Lehr Cross sectional view Heating zones Cooling zones 1200 Typical annealing temperature curve Annealing point 800 The annealing lehr is a unit designed to first reheat the container and then gradually cool it. ºF 400

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. Each mouse click adds a question and answer after the initial heading and picture appear.

Annealing The Glass Container 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. Each mouse click adds a question and answer.

Annealing Lehr Discharge Polariscope 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.” Discuss the slide. Future slides will cover temperature controls and using the annealing strain discs.

Annealing Strain Discs

Surface Treatment Cold End Application Polyethylene is sprayed between the rows of bottles. Backup sprays are also available should the first unit fail to apply treatment. A diffusion hood is used to keep spray from the bottom backup unit reaching the finish of the bottle.

Surface Treatment Spray Head Location Spray head must be below finish. Lehr conveyor mat Diffusion hood airflow must be sufficient to keep treatment off of the finish.

Inspection Automatic 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 BULK Bottles are placed onto tier sheets and stretch wrapped with plastic. Various types of corrugated packages

QUESTIONS?