What happens to my glass
The glass banks are emptied by a multi-compartmental vehicle to ensure that the green, clear and brown glass is kept separate. The glass is then taken to Harlow for reprocessing:
Step 1: Glass Melting
The furnace melts cullet (crushed, recycled glass), sand, soda ash, limestone, and other raw materials. A modern glass furnace can reach temperatures of 2,800° F and have a capacity of 300 tons of molten glass.
Step 2: Container Forming
A Refiner distributes molten glass to an area called the fore hearth, which brings the temperature of the molten glass to a uniform level. A Shearing and Distribution System cuts molten glass from the fore hearth into uniform gobs and sends them to an I.S. (Individual Section) Forming Machine that forces the molten gobs into the mould shape. The glass drops below 2,100° F and formed glass containers leave the machine, crossing a cooling plate where they are cooled rapidly to below 900° F. The glass has now passed from liquid to solid form.
Step 3: Container Conditioning
The formed containers are loaded into an Annealing Lehr, where they are reheated to nearly the melting point, then cooled gradually. This reheating and slow cooling eliminates internal stress making the containers stronger and more shock resistant.
Step 4: Surface Treatment
The temperature of the containers is reduced to between 225 and 275° F. Cold End Sprays apply an exterior coating to the bottles to increase line mobility and reduce abrasions. This maintains the inherent strength of the container.
Step 5: Automatic Inspection
The Fast Cooling Section cools the containers to about 100° F - cool enough to touch. The containers then pass through instruments that perform physical and optical tests. Rejected containers are immediately re-melted.
Step 6: Product Handling & Packaging
A Case Packer packs the containers in corrugated cases. These are sent to a Case Palletiser, where they are stacked in a prearranged pattern for stability. A strapper fits plastic bands around the stacked boxes for added stability and finally, the Stretch Wrap Unit covers the stacked boxes with plastic wrap. Containers can also be sent to a Bulk Palletiser that stacks the individual containers in 5 to 15 layers. Bulk loads are also strapped for stability and sent through the Stretch Wrap Unit before shipping.