Recycled glass called cullet is stored in bays, along with other core raw materials including silica sand, soda ash, limestone.
The core ingredients of silica sand, soda ash, limestone and a large amount of recycled glass called cullet, are mixed into a precise batch formulation. More ingredients can be added to create different colours of glass.
The prepared batch travels along a conveyor belt to the furnace, which melts the raw materials at 1565ºC, for 24 hours. Now ready for forming, the molten glass is distributed to a forehearth, where it’s conditioned and equalised into a uniform temperature.
Streams of molten glass enter a feeder and are pushed down a narrow tube by a plunger. As they emerge, mechanical shears cut them into gobs, before going to blank molds in the forming machine to create partially shaped molten glass called parisons. There are two methods of forming. The ‘Press & Blow’ method and ‘Blow & Blow’ method.
Loaded into the annealing lehr, the bottles are heated again and then cooled to room temperature, relieving internal stress and improving durability.
Moving along to the automated inspection area, careful monitoring involves a comprehensive range of electronic, mechanical and manual checks to ensure bottles are of the highest quality, and any that don’t pass the test are returned for recycling.
All the bottles are automatically packed into pallets, then housed in our on-site warehouse. From the warehouse pallets of bottles are either shipped to customers or in Elton can be sent to the filling hall.
Our range of distribution services can deliver glass direct to our customers for filling or filled products to distribution centres or direct to retailers.
Glass is a material that comes from mixing various natural minerals such as soda, silica sand, limestone, and the recycled glass itself. The glass-making process uses furnaces that reach temperatures of 1600°C where these elements fuse together. Once the melted glass is created it can be moulded into whatever is needed, whether it is a jar, bottle or window. The first signs of glass date back many thousands of years…
Encirc is leading the way in utilising “Cobots” to help in its glass making process. Cobots are robots that work alongside humans. Encirc is one of the early adopters of cobots and uses them at the heart of its glass making process to assist the operator complete repetitive tasks safely.
Industry 4.0 Line
In 2020 we launched the world’s first industry 4.0 glass production line. The line will be equipped with the best industry technology, being able to talk to each other to correct faults, increase efficiency and truly set the standard for global container glass production.
Our virtual reality room is used to train our glassmakers in a safe virtual environment. The hi-tech equipment means new recruits can get up to speed on how to run glassmaking machines without having to disrupt production.