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Main Processes and Future Development Prospects of Glass Container Manufacturing
2023-08-14

Since the beginning of the 21st century, with the further deepening of China's reform and opening-up policies, the country's economic development has been progressing at an unprecedented rate, resulting in remarkable achievements that have captured global attention. During this period, the daily glass industry has blossomed like spring flowers, undergoing rapid development. Several well-established enterprises have demonstrated promising trends in terms of both equipment levels and production capacities. By 2008, China's production of daily glass products had reached an impressive 1.4457 million tons. However, there still exists a significant number of enterprises within the industry with relatively low overall standards, leading to a lack of cohesive development.

 

In recent years, significant changes have occurred in the international glass container industry, particularly the wrapping film sector. The demand for glass containers, both domestically and internationally, continues to rise. However, the expectations for product quality have grown higher. These shifts have presented new development opportunities for the daily glass industry. Consequently, effectively addressing these emerging trends, defining the future direction, and further elevating the industry's overall standards are critical challenges at present.

 

The following discussion will delve into the future development of China's glass container manufacturing processes and configurations. This collective exploration aims to stimulate rapid and effective progress in the industry's technological advancement. Developed countries with advanced levels of the daily glass industry have already established mature developmental paths. In light of this, China can adopt a "learn from the advanced, adapt to the local" perspective, selectively assimilating their experiences and innovating our own development. The ultimate goal is to establish China as a leading nation in the daily glass industry.

 

**Batching Process**: The selection and preparation of glass raw materials adhere to strict, standardized scientific processes that are pivotal to the quality of glass products. Variables such as particle size, purity, specifications of pure glass, cleanliness, impurity content, and color directly influence glass quality. The accuracy and stability of raw material selection and batching procedures are fundamental to product quality, environmental preservation, and civilized production. Many enterprises tend to overlook the batching process during their investment phases, particularly when labor costs are low. This oversight can result in inaccurate material composition and measurement, uneven blending, compromised glass liquid quality, substantial environmental pollution from dust, and latent occupational health hazards. Automated batching systems are already widely used internationally, and China possesses mature experiences in this realm. For large-scale glass production operations with the necessary conditions, a gradual transition to computer-controlled batching systems is recommended to replace manual batching.

 

**Glass Furnace**: The glass furnace serves as the heart of the glass industry and is the primary energy-consuming equipment. Currently, flame furnaces are predominant in China, exhibiting relatively high energy consumption (typically around 300-500 kg of standard coal per ton of finished product, compared to the international advanced level of around 150-200 kg of standard coal per ton of finished product). The melting rate is low, and the cycle melting rate is similarly low. These factors are influenced by enterprise product structures, furnace size, and rational production line configurations. In terms of energy sources, China mainly relies on coal and oil, which yield low heat utilization efficiency and significant pollution. Conversely, international practices commonly embrace clean energy sources such as natural gas and electricity, resulting in higher heat utilization efficiency and reduced pollution. Even enterprises using oil as fuel often adopt technologies like electric boosting and pure oxygen combustion to enhance thermal efficiency, increase melting rates, and minimize pollution. Furnace lifespans in China typically range from 4 to 6 years, whereas international advanced levels tend to be around 10 years, with some furnaces surpassing 12 years. Of course, while refractory materials and initial investment costs might be higher, the overall cost-effectiveness might be superior compared to the investment required for furnace shutdowns and major repairs every 4 to 5 years. China should tailor its approach, incorporating targeted insights from international advanced experiences to suit its national context. Automatic control systems for glass furnace operations are indispensable for improving melting quality, extending furnace lifespans, and optimizing energy efficiency and emission reductions. It's notable that the majority of China's furnaces lack automatic control systems, whereas foreign counterparts widely implement automated control technologies for the glass melting process.

 

**Forming Process**: The forming process has a significant impact on product quality. In manual techniques, such as glassware and specialized shaped bottles, limitations arise due to relatively low cultural literacy among industry personnel. This impacts both the technical and artistic components of the products. Among machine operators, variable technical proficiency levels exist. Many possess surface-level knowledge of forming techniques and the entire glass manufacturing process, lacking comprehensive understanding. This impedes the elevation of product quality and pricing, resulting in limited value addition. Enterprises urgently need to strengthen their internal capabilities through enhanced training, thereby comprehensively improving employee technical proficiency and skills. By responding to market demands, diversifying product varieties, increasing technological investments, emphasizing product quality improvement and innovation, China can significantly enhance its international market position in the daily glass industry.

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