Operational characteristics of the NNPB plunger in the glass container industry.

Although glass containers are an everyday item the process responsible for their production is not scientifically understood. Developments have occurred slowly over many years, mostly on a trial and error basis and in response to economic pressures. The narrow neck press and blow (NNPB) process has evolved in recent years as a result of attempts to reduce container weight. The fundamental component of the NNPB process is the plunger which is responsible for the initiation of the cavity and control of glass distribution within the container.The NNPB plunger functions as a form tool and as a heat exchanger, thus requiring a carefully selected range of properties. The Engineer responsible for tooling selection and operation has a limited resource of scientific knowledge to enable the performance of the process to be optimised.The current NNPB plunger is subject to high rates of wear and is directly responsible for product defects, thermal instability and limits process speed.The work presented here is a scientific study of current NNPB plunger technology. The plunger has been investigated in relation to the requirements of the glass container forming process. The materials used have been examined, before and after use and their wear modes explained. The thermal properties of the plunger have, as far as is possible, been examined during the forming cycle. When combined with results from the characterisation of transformations occurring in the material, during its service life, operational requirements have been explained. The ability of the NNPB plunger to remove heat from the glass has been investigated, and has illustrated significant deficiencies in the current arrangement. Details are given as to how these deficiencies may be overcome to enable the Engineer to regain control of the process.As a result of the study many phenomena exhibited by the NNPB plunger are now understood and may be related to the performance of the process.