Stones: Defect Analysis in Soda-Lime Glass

Introduction

This project focused on addressing solid inclusion defects in flat glass manufacturing, specifically alumino-silicate nature defects such as spinel, corundum, cristobalite, and wollastonite. These defects significantly impact product quality and yield. By studying the intrinsic petrographic properties of these inclusions through thin sectioning and microscopic analysis, the project aimed to identify their sources and develop strategies for defect reduction.

Methods

• Source tracing — Used composition analysis to determine the root causes of the solid inclusion defects.
• Process optimization — Correlated defect occurrences with process parameters to identify optimal manufacturing conditions.
• Yield improvement — Worked to minimize defect formation through targeted corrective actions and process improvements.

Results

• Yield Improvement — A comprehensive understanding of the defects and their sources led to a 2% reduction in defect losses.
• Process Insights — Defects were plotted across the width of the glass ribbon, revealing contamination patterns and enabling targeted investigations.