For centuries glass bottles and jars have been produced by blowing air into a glob of melted material. This procedure in modern industry is done with equipment that uses high speed molds and compressed air for the production of thousands of pieces per day. Vacuum has recently been introduced to faster molding processes obtaining better shapes, lighter/thinner glass and lower compressed air requirement for an optimized production cycle.
Thanks to vacuum, glass bottles and jars can be molded into thin and light shapes at very high speeds. Traditionally, glass molding is done with compressed air, which blows air into a glob of melted material. This procedure has worked well for centuries, but thanks to vacuum the process becomes faster, more energy-efficient and at lower production costs. Find out how vacuum shapes the world of glass manufacturing.
Glass bottles and jars are produced by high speed “Individual Section” (IS) machines. A glob of melted glass is dropped in a mold, compressed air blows the glob to the mold’s shape and the finished bottle is removed. In principle, all the IS machine needs a supply of compressed air, but thanks to vacuum the process becomes faster and more efficient.
By applying vacuum to the process, the production line requires up to five times less air and energy. Thanks to vacuum the IS machine also operates faster and the quality of the finished glass bottle or jar ends up being better.
We ran various test, in the lab and with our customers, and found out a rotary screw pump with variable speed drive is the most energy-efficient solution for glass bottle manufacturing. The GHS VSD+ rotary screw vacuum pump is an electricity-saver: the GHS VSD⁺ series have shown a significantly better performance against traditional fixed speed technologies; potentially saving 50%* or more in energy costs, in most applications compared to traditional fixed speed vacuum technologies. Don’t take our word for it, with a Vbox energy audit tool, you can calculate the energy savings for your specific application.
These are the direct benefits to your container glass production line:
*In most applications compared to traditional fixed speed vacuum technologies based on measurement with our Vbox energy audit tool.
Rotary vane vacuum pumps are traditionally the technology of choice for glass molding and use in IS machines. However, unregulated rotary vane pumps cannot follow fluctuating demands and pressure changes throughout the process. A rotary vane pump is what we call “fixed-speed” technology, which means it always runs full throttle, to achieve the deepest vacuum level it was designed for. As a result, if there are natural fluctuations in demand, these pumps are technologically limited in their controllability and can only be controlled within a relatively narrow predefined rotational speed range.
An oil-sealed screw vacuum pump, on the other hand, is able to run through a wide range of rotational speeds due to its rotor profile and can always obtain the optimum operating point. This creates stable pressure conditions with reduced energy consumption.
Would you like to take your glass production installation to the highest level? Then you should consider a centralized vacuum system. A central control system controls and monitors various pumps simultaneously, ensuring the optimal mix of machines is running at all times. The vacuum supply matches the exact demand of the application, while overall energy consumption is optimized. On top of these energy-savings, a centralized vacuum system offers you pressure stability, resulting in a more stable production, especially during mold changes or other short breaks. A stable and reliable vacuum supply also benefits the end quality of the glass.
At Atlas Copco, we are used to partnering up with our customers to work out the best possible solution for their specific need. If you’re in the glass industry, we can help you with your complete installation: from design to aftersales service and maintenance. We're looking forward to hearing about your next project.
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