Birth of a Bottle

Birth of a Bottle

Right now we are going to the large factory making bottles in Novosibirsk, Russia.

The factory started its work in 1954 as a maker of optoelectronic devices, cathode-ray tubes for oscillography and television picture tubes. In 1994 the mass production of TV equipment was over in Russia and the factory was repurposed to make glass jars.

Today the factory “Ekran” has a leading position among manufacturers of glass jars on the territory from the Urals to the Russian Far East.

They make bottles for alcoholic and non-alcoholic beverages, cans for juice, sauce and other products with capacity from 0,25 litres to 3 litres; bottles from brown glass.

Birth of a Bottle

Birth of a Bottle

This is a glass furnace.

Birth of a Bottle

The output of the factory is 620 million glass jars a year. It’s about 1,7 million items a day.

Birth of a Bottle

The output of the glass furnace is about 180 tons of glass mass a day.

The technology consists of the following major processes:

– preparation of raw materials;
– preparation of furnace charge (dry mixture of materials put into a furnace for making glass mass),
– glass mass boiling,
– fritting and formation of products;
– quality control and packing.

Birth of a Bottle

Glass mass is just taken from the furnace.

The furnace charge is heated to 1100-1600 C for making glass mass.

Birth of a Bottle

Color of glass depends on additives.

The process of making glass mass is rather smelly, by the way.

Birth of a Bottle

Then the glass mass is cooled down to become viscous. Those streams below are future bottles.

Birth of a Bottle

This is a process of making glass drops.

Birth of a Bottle

Birth of a Bottle

The ready glass mass is delivered to the forming machines.

Birth of a Bottle

Birth of a Bottle

This line consists of ten sections. It makes brown glass bottles.

Birth of a Bottle

The products undergo another thermal treatment in direct heating furnaces.

Birth of a Bottle

Birth of a Bottle

The bottles are sprayed with special solution that prevents scratches and scuffs on the bottles during transportation.

Birth of a Bottle

The products are ready to undergo quality control.

Birth of a Bottle

These machines scan parameters of each bottle to assure they meet all requirements of customers.

Birth of a Bottle

Packed products.

Birth of a Bottle

There is also another shop where transparent bottles and cans are made and where quality control is performed manually.

Birth of a Bottle

The birth of a 2 litres can.

Birth of a Bottle

Birth of a Bottle

Birth of a Bottle

These ones are for vodka.

Birth of a Bottle

Quality control.

Birth of a Bottle

And ready products.

We also recommend you to see this video:

via dedmaxopka

4 thoughts on “Birth of a Bottle”

  1. Why aren’t there any comments on this page? These photos are awesome!
    Seriously, being able to see the metamorphis of glass is just cool, especially when it’s interesting to see how the machines were designed to do their job.

  2. Really nice series of photos. So the seam on beer bottles is from the mold opening. I had previously thought that bottles are made from two halves.

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