What is glass

GOOD MORNING

Eng.Magdy Abdelsattar 1

Professional Profile
Eng. Magdy AbdelSattar Omar,
 Location: Cairo-Egypt
 Experience:20 years of experience managing business unit and
commercial divisions, supported with Solid academic foundation (EMBA).
 Educational background: B.SC degree in engineering coupled with
Executive MBA, major Marketing strategy’s formulation and
implementation
 Business Specialties: Sales, Marketing, Business Development, Product
/Brand Management, Customer service, and Operations Management.
 Business industry: telecommunications, FMCG, & household appliances
business in the Egyptian market
Profile:
 Proven experience and knowledge of telecommunications, household appliances,
and FMCG business in the Egyptian market.
 15 years of experience as professional Management at multinational environment .
 Fully awareness and skilled with planning, organizing, controlling, and leading skills.
 Proven experience in building new business from scratch in the Egyptian market.
 Reliable awareness of the Gulf area market "customers culture and habits"
acquired during his 12 years living in Kuwait,


What is glass
Agenda

What is glass and how is it produced.
Main properties of glass.
Types of glass and market applications.
Glass manufacturing
Business tips


WHAT IS GLASS AND
HOW IS IT PRODUCED


Glass is a hard material normally
fragile and transparent common
in our daily life. It is composed
mainly of sand (silicates, SiO2)
and an alkali


These materials at high
temperature (i.e. molten viscous
state) fuse together; then they
are cooled rapidly forming a
rigid structure.


Glass is used for:
architecture application,
illumination,
electrical transmission,
instruments for scientific research,
Optical instruments,
domestic tools and even textiles.

Glass does not deteriorate, corrode, stain or fade and
therefore is one of the safest packaging materials.


the common ingredients to obtain
glass:
 1. Sand (SiO2 silica)
In its pure form it exists as a polymer, (SiO2)n.

 2. Soda ash (sodium carbonate Na2CO3)
Normally SiO2 softens up to 2000°C, where it starts to degrade (at
1713°C most of the molecules can already move freely). Adding soda
will lower the melting point to 1000°C making it more manageable.

 3. Limestone (calcium carbonate or CaCo3) or dolomite (MgCO3)
Also known as lime, calcium carbonate is found naturally as limestone,
marble, or chalk.
The soda makes the glass water-soluble, soft and not very durable.
Therefore lime is added increasing the hardness and chemical durability
and providing insolubility of the materials.


MAIN PROPERTIES OF
GLASS


the main characteristics of glass
 Solid and hard material
 Disordered and amorphous structure
 Fragile and easily breakable into sharp pieces
 Transparent to visible light
 Inert and biologically inactive material.
 Glass is 100% recyclable and one of the safest packaging materials
due to its composition and properties

These properties can be modified and changed by
adding other compounds or heat treatment.


TYPES OF GLASS AND
MARKET APPLICATION


Type of glass
Chemistry % by Weight of the most common types of
glass

Element Type of glass

Fused Soda-lime Boro-silicate Alumo lead borate
silica silica glass silicate glass glass

SiO2 100% 60- 75% 70-81% 62% 54-65%
Al2O3 1% 2-7% 17% 2%
CaO 5-12% 8%
MgO 4% 7%
Na2O 12-18% 4-8% 1% 13-15%
K2O
B2O3 7-13% 5%
PbO 18-38%

Commercial glass or Soda-lime glass
This is the most common commercial glass and less
expensive. The composition of soda-lime glass is
normally 60-75% silica, 12-18% soda, and 5-12% lime. A
low percentage of other materials can be added for
specific properties such as coloring
It has light transmission appropriate to be use in flat glass in
windows;

It has a smooth and nonporous surface that allows glass bottles and
packaging glass to be easily cleaned;

Soda-lime glass containers are virtually inert, resistant to chemical
attack from aqueous solutions so they will not contaminate the
contents inside or affect the taste.

soda-lime glass does not allow light at a wavelength of lower than
400 nm (UV light) to pass.


Commercial glass or Soda-lime glass

The disadvantages of soda-lime glass is that
is not resistant to high temperatures and
sudden thermal changes.

soda-lime glass is primarily used for bottles, jars,
everyday drinking glasses, and window glass.


Lead glass
is composed of 54-65% SiO2, 18-38% lead oxide (PbO),
13-15% soda (Na2O) or potash (K2), and various other
oxides. When the content of PbO is less than 18% is
known as crystal glass
In moderate amounts lead increases durability;

In high amounts it lowers the melting point and decreases the
hardness giving a soft surface;

In addition it has a high refractive index giving high brilliance glass.

Glass with high lead oxide contents (i.e. 65%) may be used as radiation
shielding glass because lead absorb gamma rays and other forms of
harmful radiation, for example, for nuclear industry.


Borosilicate glass
is mainly composed of silica (70-80%), boric oxide B2O3
(7-13%) and smaller amounts of the alkalis (sodium and
potassium oxides) such as 4-8% of Na2O and K2O, and
2-7% aluminum oxide (Al2O3).
Boron gives greater resistance to thermal changes and chemical corrosion.

It is suitable for industrial chemical process plants, in laboratories, in the
pharmaceutical industry, in bulbs for high-powered lamps, etc.

Borosilicate glass is also used in the home for cooking plates and other heat-
resistant products.

It is used for domestic kitchens and chemistry laboratories,

it has greater resistance to thermal shock and allows for greater accuracy
in laboratory measurements when heating and cooling experiments

GLASS
MANUFACTURING


modern glass container factories are
three-part operations
 batch house
handles the raw materials.

 hot end
handles the manufacture proper — the furnaces, annealing ovens,
and forming machines, is where the molten glass is formed into
glass products

 cold end
handles the product-inspection and -packaging equipment.


Glass manufacturing process


Batch house
 Whether automated or manual, the batch
house measures, assembles, mixes, and delivers
the glass raw material recipe (batch) via an array
of chutes, conveyors, and scales to the furnace.

 The batch enters the furnace at the 'dog house'
or 'batch charger'.

 Different glass types, colors, desired quality, raw
material purity / availability, and furnace design
will affect the batch recipe.


Hot end
 Furnace:

 The furnaces are natural gas - or fuel oil -fired, and
operate at temperatures up to 1,575°C.

 Typically, furnace
"size" is classified by metric tons
per day (MTPD) production capability.

 Types of furnaces used in container glass making
include 'end-port' (end-fired), 'side-port', and 'oxy-
fuel'.


Hot end
 Forming process
There are, currently, two primary methods of making a glass container

 blow and blow method used for narrow neck
containers only
 press and blow method used for jars and
increasingly narrow neck containers


Hot end
Forming machines
The forming machines hold and move the
parts that form the container. Generally
powered by compressed air, the mechanisms
are timed to coordinate the movement of all
these parts so that containers are made

The most widely used
forming machine
arrangement is the
individual section machine
(or IS machine).


Hot end
 Internal treatment

 After the forming process, some containers,
undergo a treatment to improve the chemical
resistance of the inside, called internal treatment or
dealkalization.
 usually accomplished through the injection of a
sulfur- or fluorine-containing gas mixture into
bottles at high temperatures.


Hot end
 Annealing

 As glass cools it shrinks and solidifies.

 Uneven cooling causes weak glass due to stress. Even cooling is
achieved by annealing.

 An annealing oven (known in the industry as a Lehr) heats the
container to about 580°C then cools it, depending on the glass
thickness, over a 20 – 6000 minute period.


cold end
 The role of the cold end is to:
 Inspect
 Secondary processing
 Package
 Coatings
 Label
 Ancillary processes – compressors & cooling


BUSINESS TIPS


Tips
 Glass container manufacture in the developing world is a growing
market business.

 Glass container manufacture is also a geographical business; the
product is heavy and large in volume, and the major raw materials
are generally readily available, therefore production facilities need
to be located close to their markets.

 A typical glass furnace holds hundreds of tones of molten glass, and
so it is simply not practical to shut it down every night, or in fact in
any period short of a month.

 Factories therefore run 24 hours a day 7 days a week. This means
that there is little opportunity to either increase or decrease
production rates by more than a few percent.

Tips
 Furnaces and forming machines cost tens of millions of dollars and
require at least 18 months of planning.

 There are usually more products than machine lines means that
products are sold from stock.

 The marketing/production challenge is therefore to be able to
predict demand both in the short 4-12 week term and over the 24-
48 month long term.

 In mature market business there is usually a factory per 1-2 million
people. A typical factory will produce 1-3 million containers a day.


EGYPT’S GLASS
INDUSTRY


Strengths
 Highest quality sand in the world and
also high quality limestone.

 Virtually all input materials required to
produce glass are available domestically.

 Egypt has a strategic location within
three regional markets: Europe; Middle
East; and Africa.

 Strong export performance in glassware
product.


Weaknesses
 The lack of a recycling system for glass products, in particular
bottles and jars, is creating significant problems for Egypt’s glass
manufacturers as they are having to operate their furnaces at
lower levels of recycled inputs than is specified by the furnace
manufacturers.This results in higher manufacturing costs and
lower quality glass products.

 Alexandria Sodium Carbonate Co. is the only domestic producer
of soda ash and is unable to meet domestic demand. Significant
quantities of soda ash are being imported.

 Restrictions on the availability of certain dimensions of
domestically produced clear float glass, and all colored float glass is
imported. Imports of all types of float glass have been increasing.

 Lack of a domestic high performance glass sub-sector, with this
weakness applying more to building, than auto, glass.


Weaknesses
 High dependence on imports of bulbs and tubes
for domestic electric lighting manufacture.

 Lack of R&D activities that are being applied
commercially.

 Shortage of trained chemical – engineers
required to support the development of the
industry.

 Overall weakness in flat glass production and
products, resulting in weak exporting
performance in this product area.


Opportunities

 New projects to:

 Increase bottle manufacturing capacity.
 Add new production capacity for jars and bottles, this could be based on
further phases of the new facility indicated above with the potential of
having four furnaces, each with a capacity of 27,375 tones.
 New production capacity for electric lighting glass.
 Add at least one new float production line.
 Produce high performance glass.
 Develop fiber glass manufacturing capability.


Opportunities
 New soda ash production facility, in addition to the extra 35,000 tones capacity
that will start operating.The region, as a whole, is a significant net importer of
soda ash of about 1 mn tones a year, with the potential for Egypt to become a
major player in this product.

 Egypt’s Glass Industry to emulate the export-led growth of Turkey’s Glass
Industry, with Egypt’s industry changing from being a net importer of glass
products, to a significant net exporter. Specifically, continue to develop Egypt’s
strength in glassware products, and turn the current weakness in flat glass
products into a strength.

 Establish a link between having a leading regional research and development
capability in life cycle costing of buildings, under the concept of ―environmental
optimization in environmental services‖ , and developing Egypt as regional base
for the manufacturing of high performance glass.


Threats
 New float glass manufacturing capacity is added in the region, in
addition to the new facility being constructed in UAE, that reduces
the likelihood of having a second and possibly third float line
located inside Egypt.

 Regional high performance flat glass capabilities, for building and
auto glass, are developed in other countries which takes the
opportunity away from Egypt to become a major player in these
products.

 Auto glass produced in Egypt continues not to meet the product
quality standards and specifications of auto OEM manufacturers
outside Egypt.


THANKS


What is glass

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