I. Mold Inspection
1.Most of manufacturers specialized in producing glass alcohol bottle carry out production depending on molds provided by clients or molds newly made as per drawings and sample bottles, which may affect the key dimension of formed mold. Therefore the key dimension must be communicated and negotiated with clients when making the mold, reaching the agreement on modification opinions.
2.The mouth mold, blank mold and formed mold of all molds shall be matched before delivering into factory and shall be inspected according to drawings or client’s requirements.
II. First Article Inspection
1.2-3 products of each mold are selected from the first 10-30 products produced after loading the mold on tools and before entering the annealed wire for dimension and specification inspection, especially the mouth dimensions, inner and outer diameter of mouth, whether the lettering at the bottom is correct and clear and whether the pattern on bottle body is correct.
2.When the bottle was taken out from annealed wire, the QC leader shall select 2-3 products from formed products of each mold and carry out test from all aspects according to drawings. The key points except above contents are volume measurement, material weight measurement, inner and outer diameter of mouth. When necessary, fill up the bottle with water and use the cover provided by client for actual assembly, and test whether it can be covered in place and whether it is leaked, and carry out internal pressure, internal press, acid and alkali resistant test.
III. Process Inspection
1.When mold was not replaced, take 2 products for volume and material weight measurement every 2 hours. In addition, the inner and outer diameter of mouth shall be tested as well because the mouth mold is easy to be covered by oil dirt during the use, leading to loose cover and alcohol leakage.
2.The new mold may be replaced during the process therefore the molding workshop must immediately inform QC workshop after replacing the mold. QC workshop must carry out first article inspection and process inspection for those bottles produced by the new mold to prevent the quality problems after replacing caused by QC workshop missed leakage test.
IV. Full Inspection
After the product being taken out from the annealed wire, QC personnel (or third-party test) must carry out appearance test for all products, especially:
（1）Bottle bubble: bubble is the most common problem during the production of glass bottle. Most of QC personnel cannot master the dimension during the test, such as: the bubble ∮1mm above on the sealing surface of bottle mouth is not allowed; the bubble ∮1mm below the bottle body shall be not over 6 nos. within 1cm2; the bubble in 1mm＜∮＜6mm shall be not over 3 nos. with the distance of 20mm above; bubble on the surface is not allowed, which is difficult to control and only the Film with different shapes can be used for comparison.
（2）Bent neck: it is mainly because that mouth mold and formed mold mismatched,
（3）Sloping bottom: the material at the bottom is not even with one half and more than one half thicker, which will affect product quality and degrade the product.
（4）Width of mold seam: it is not allowed that mold seam exceeds 0.5mm of the surface and even there is a feeling of shaving hands. Especially such defect on sealing surface is not allowed. The main reason is that if formed mold not sealed in place or caused wears, it is required to re-pair, re-polish, re-finish and re-assemble.
（5）Material color: in general, the material color will not be greatly changed, except the components of used raw materials changed. It will not change generally, in case of turning green or blue, the formula can be properly adjusted to remove it.
（6）Inner and outer diameter of mouth, inner notch of mouth: the inner and outer diameter of mouth and door are easiest to fail. Outer diameter: the mouth mold is easy to be covered by oil dirt during the use, leading to anti-slip gear lessening, cover sliding to left or right, not tight. The notch is visual inside the bottle mouth, and inner plug of cover cannot be tight after inserting, which will lead to alcohol leakage, mainly because the material is too soft, or material is not fully formed due to too speedy core pulling after materials entering into the blank mold, or the core is too short, which may be solved by lengthening the core.
（7）Base material (deflective bottle): the main reasons are those materials are too hot (temperature is too high) and not totally cooling, or particles precipitated at the base after molding and forming, or the formed products were not placed at the middle of bottom.
（8）Thin shoulder: it may occur to square vase in general due to the mold design. It is mainly depending on the tanning material action and time (material color) to prevent dead angle, running and even thin shoulder. That will cause that it is difficult to control the test, lead to large breakage during the transportation or alcohol filling and sales, resulting in loss. The rubber hammer can be used to lightly knock the bottle shoulder during test, in case of any problems, immediately reflect and correct.
（9）Bottle body not shiny: the body is pitted and fogy with poor transparency, which is mainly because there is one layer of carbides on the internal surface after applying the releasing agent during the process of forming, which can be solved through finishing polish.
（10）Pitted material: the bottle body is much pitted which is mainly because the temperature of pool furnace is too low leading to materials not totally matured, or the speed of material feeding machine is too fast. Decreasing the machine speed, reducing material discharge and other measures can ensure the temperature of dissolved materials in the pool.
V. Warehousing and Sampling Inspection
The quality management personnel (or third-party test) shall carry out sampling for packaged and warehoused batch of finished products according to AQL counting and sampling plan. The all-round (upper, middle and lower parts) sampling shall be carried out as far as possible and the test shall be conducted in strict accordance with standards or client’s requirements. The conforming batches shall be warehoused timely and stacked neatly with the clear markings. The non-conforming batches shall be immediately marked, isolated and asked for returning to factory until passing the sampling inspection.
VI. Inspection For Decorating Firing Bottle
1.Turning red: this is mainly because the temperature is too high and speed of mesh belt is too slow, then the applied color remover developed the reduction reaction.
2.Poor adhesive force of stained paper: except the material of stained paper, this is mainly because the temperature is too low. The stained papers with different materials needs different temperature, therefore the temperature shall be adjusted when decorating firing.
3.Stained paper foaming: there are many pores on stained paper of bottle after decorating firing, which is because the foams in the stained foam were not removed after pasting the stained paper, or decorating firing is conducted when the water on the surface of stained paper was not dry. The diluted hydrochloric acid can be used to scrape the stained paper for those products with non-conforming decorating firing, and then repeat the process of decal and decorating firing.
4.Mixed package with different alcohol concentrations: due to the identical bottle shape and others except the concentration on stained paper, when carrying out decal, decorating firing, test and package, it is easy to mix the package of bottle with different alcohol concentrations, causing client’s complaint and quality accident.
Post time: Dec-21-2021