1- Raw-Material Selection

Silica sand with an ultra-low-iron SiO₂ purity of at least 99 % forms the backbone of our flint glass bottles, giving premium liquor brands the crystal brilliance they demand. The silica is blended with carefully metered amounts of soda ash, limestone, dolomite, feldspar, borax, barium and trace alumina to fine-tune melt viscosity, colour and impact strength, while recycled post-consumer cullet—up to 30 % of every batch—lowers furnace energy by more than 15 % and cuts CO₂ emissions by roughly 300 kg per tonne of glass, reinforcing our circular-economy credentials. Ferrous contaminants are extracted by rare-earth magnets and cyclone dust collectors capture sub-10 µm fines, ensuring a perfectly clean, defect-free melt.

2 - Batch House and Continuous Batching

In a sealed, computer-controlled batch house, loss-in-weight feeders dose each raw material to within ±0.1 %, preventing colour drift or density variation. The ingredients are homogenised in dehumidified air to stop borax or soda ash from clumping, then transferred by enclosed conveyor directly to the melting furnace. Each lot is time-stamped and linked to our ERP system for end-to-end traceability, while inline colourants for emerald or amber runs are premixed to keep hue variation below ΔE 1.0 and eliminate costly off-shade rejects.

3 - High-Temperature Melting

Oxygen-fuel regenerative furnaces operating between 1 550 °C and 1 600 °C convert the batch into a crystal-clear, bubble-free glass that meets ISO 9001 clarity standards. Infra-red pyrometers and digital cameras feed real-time data into the PLC, keeping temperature within a 3 °C window and slashing NOₓ emissions by up to 80 % compared with conventional air-fuel units. Dedicated forehearth stirrers homogenise temperature and chemistry, while on-the-fly forehearth colour dosing supports short-run limited-edition bottle campaigns without line stoppage.

4 - Gob Feeding

A servo-driven feeder shears molten glass into perfectly formed gobs whose weight deviates by no more than ±0.5 g from the target bottle volume. Dual-zone conditioning air-knives stabilise gob surface temperature, minimising parison defects such as bird-swings, while platinum-rhodium bushings extend feeder life and prevent seed-type inclusions that can mar top-shelf bottles.

5 - Forming on I.S. Machines

Eight- to ten-section dual- and triple-gob I.S. machines deliver up to 450 bottles per hour per section—more than 150 million units a year—without sacrificing dimensional accuracy. Variable-finish mould carriers allow rapid changeovers between cork, MCA or GPI threads in under twenty minutes, providing true agility for OEM and ODM spirits lines. Real-time lubrication and gob-temperature analytics stream into our MES dashboard, predicting mould wear before downtime occurs, while in-blow hot embossing presses brand logos or QR codes directly into the glass for built-in anti-counterfeit security.

6 - Annealing

Freshly formed bottles enter a spline-curve-controlled lehr starting near 500 °C, where a carefully engineered temperature profile equalises cooling through the wall, eliminating residual tensile stress and boosting thermal-shock resistance. Positive-pressure atmosphere keeps airborne dust away, and a duplex tin-oxide plus polyethylene-wax cold-end coating increases scratch resistance by up to 300 %, a must for high-speed filling and returnable glass programmes.

7 - Inspection and Quality Assurance

At the cold end, 360-degree vision cameras and laser wall-thickness gauges inspect every bottle at more than 800 units per minute, capturing defect images for Six-Sigma analysis and alerting operators if CpK drifts below 1.33. Vacuum and pressure testing certify leak tightness down to 10-⁶ mbar·L / s, and automated top-finish gauges measure bore diameter, sealing surface and thread pitch to within ±20 µm, guaranteeing compatibility with T-cork, ROPP and tamper-evident closures. Bottles that fail inspection are routed back as cullet; premium lines receive a final human check to ensure flawless shelf appeal.

8 - Packing and Shipment

Approved bottles are loaded by robotic case-packers into double-wall corrugated cartons with honeycomb dividers, or palletised on ISPM-15-compliant timber for export. Humidity-indicator cards verify dry conditions throughout ocean transit, while our WMS optimises container cube utilisation, generates real-time ETA notifications and enforces FIFO rotation for just-in-time deliveries to spirits bottling plants worldwide.