Toughened Glass
| Product Code | 94107 |
| Quality and Standards | IS 2553:1971 IS 6180:1971 IS 6640:1972 |
| Production Capacity: Qty. | Quantity: 4,80,000 sq.ft. Value : Rs.1,98,00,000 |
| Uploaded on | July 2007 |
Introduction
Toughened glass acquires a degree of strength for excess of the strength of normal glass sheet or plate glass, which if broken shatters into small and comparatively harmless pieces. It is claimed that the resistance to mechanical stock of toughened plate glass is 4 to 5 times more than that of ordinary plate glass. A toughened glass has better resistance to the vibration, mechanical shock and abrasion.
Toughend Glass has to pass the following important tests :
- Transfer strength test on sheets on simply supplied (Modules of rupture and electricity)
- Impact test: By following weight on sheets supported on two wooden battens
- Impact by falling weight on sheet evenly bedded (on putty)
- Impact by falling weight on edge of sheet
- Repeated twisting tests
- Sand blast abrasion
- Thermal tests
Because of the strength and other specific physical properties mentioned above, it finds applications in the following fields:
i. Automobile : Cars, trucks, industry buses, tempos etc.
ii. Railways : Coaches
iii. Defence : Fleets, vehicles factory
iv. Commercial : Hotels, shops complex
v. Air ports : Doors
Market Potential
With increased transportation facilities the demand of the product is increasing at a steady pace specially in the automobile industry, railways, ships building both for production and replacement.
Basis and Presumptions
The project is based on single shift of 8 hours with 300 working days.
Implementation Schedule
Activity |
Period(in months) |
| Project preparation and acquirement of shed, provisional registration etc. | 2 |
| Procurement of machinery and raw materials | 6 |
| Installation of machinery and equipment, appointment of labours etc. | 2 |
| Procurement of raw materials and starting trial production | 1 |
| Total | 11 |
Technical Aspects
Process of Manufacture
The glass plate is heated to a temperature above its softening point and then subjected to rapid cooling. The glass is suddenly chilled and in this process contracts towards the core. It stretches until it has solidified and is no longer able to contract further at this stage the core is still soft. It contracts against restrained exercise by the solidified upper layer of the glass. This compression is responsible for the strength of the glass sheet, which is limited to about 20,000 lb/sq.inch. Thus it is highly stressed and the resultant force is able to nullify the external impact.
The intensity of the stresses depends on the rate of cooling, co-efficient of expansion, thermal conductivity of the glass, its specific heat, elasticity, and certain other physical properties.
Toughening Process
The raw plate glass sheet which is free from waviness, distortion etc., is cut to required size and shape and then all the edges are ground and polished as per end use of the product. This is called edge grinding and polishing and is very important for toughening because it will lead to breakages during process. No glass sheet can be toughened without edge grinding and polishing.
Washing and Drying
After the edge grinding and polishing the glass sheets are washed manually or by machine and then dried. The glass sheets are fed into the furnace (Electrically operated). The sheets are kept in the furnace above its softening point, which varies according to the composition of glass. After attaining required temperature the glass sheets are removed out of the furnace and placed in the air blowing quenching boxes for 20 to 25 seconds. After quenching glass sheet is toughened. For bend glass toughening, the glass sheets passes through a set of dies (as per shape) after furnace and then to the quenching boxes.
Quality Control and Standards
IS 2553:1971
IS 6180:1971
IS 6640:1972
Financial Aspects
A. Fixed Capital
Land and Building |
(Rs.) |
|
| Land | About 3000 sq.mtrs. @ Rs.2000 | 6000000 |
| Built up area | Work shed = 400 mtrs @ 4000 | 1600000 |
| Building, workshop 100mtrs @ 3000 | 300000 | |
| Laboratory block 40 mtrs. | 110000 | |
| Boundry wall | 100000 | |
| Water Tank | 100000 | |
| Total | 8210000 | |
Plant and Machinery
Particulars |
Imp/ Ind. |
Qty. |
Value (Rs.) |
| Electric toughening furnace complete with refractory lining, heating elements, thermo-couples, recorders, operating panel board, oil circuit breaker, temperature controller etc. to heat the sheet glass at its softening point as per following specifications: | Ind. | 1 | 2000000 |
| Maximum kW: 185 | |||
| Maximum temp. 800ºC | |||
| No. of zone: 6 | |||
| Maximum sheet glass size: 84” x 36” (7'x 3') | LS | ||
| Electric supply: 400/440V, 3 phase | LS | ||
| Air quenching blower with motor dia 1450 mm, motor 175 HP for cooling heated glass | Ind. | 1 | 550000 |
| Super structure and ducting (Fabricated locally) | Ind. | 1 | 250000 |
| Hydraulic equipment for curved sheets | Ind. | 1 | 600000 |
| Blowing boxes and moulds for curved sheets | Ind. | 1 set | 80000 |
| Edge working machine for edge arising with motor, starter, grinding wheel, water tough and V belt | Ind. | 2 sets | 120000 |
| Vertical notching machine complete with motor, starter, V belt etc., for edge working | Ind. | 1 | 80000 |
| Vertical grinding machine complete with motor, starter, V belt etc., for edge working | Ind. | 1 | 80000 |
| Vertical polishing machine with motor, starter, V belt etc. | Ind. | 1 | 80000 |
| Drilling machine for drilling holes in the sheet glass for shaping suitable drilling 1” bore with 3” x 2” cast iron table with 10”/12” drilling centre | Ind. | 1 | 100000 |
| Cutting machine with arm table, cutting rail and swivel cutting head for shaping | Ind. | 1 | 100000 |
| Drying and washing machine with blower, starter, heater conveyor, roller etc., for washing and drying the sheets | Ind. | 1 | 200000 |
| Testing equipments | Ind. | ||
| Rectification machine to detect surface scratch | Ind. | 1 | 40000 |
| Polariscope inspection line with poloroid sheet, light etc., for testing the strain/in the glass | Ind. | 1 | 35000 |
| Other testing equipments for testing | Ind. | 1 | 30000 |
| Maintenance and workshop machines | Ind. | 1 set | 80000 |
| Lathe machine complete with accessories | Ind. | 1 | 180000 |
| Pillar drilling machine | Ind. | 1 | 20500 |
| Power saw machine 10” | Ind. | 1 | 20000 |
| Hand drill 25 mm size | Ind. | 1 set | 10000 |
| Hand grinder 6” size | Ind. | 1 | 10000 |
| Tools for die making | Ind. | LS | 20000 |
| Bench vice | Ind. | 2 sets | 8000 |
| Compressor | Ind. | 1 | 50000 |
| Pumps for water supply | Ind. | 2 | 50000 |
| Total | 4703500 | ||
| Electric Sub-station | |||
| LT panel | |||
| Electricals like busbar, distribution board, main switch, cables etc. | 1000000 | ||
| Taxes, freight octroi, transit expenses and handling including transformer 10% | 300000 | ||
| Erection and commissioning such as unit construction, steel structures etc., and supervisory charges 7% | 225000 | ||
| Electrification charges 7% | 225000 | ||
| Contingencies and price escalation 5% | 150000 | ||
| Misc. equipments such as trolleys, glass cutting tables etc. | 50000 | ||
| Office equipment like typewriter,almirah, furniture, trolleys for carrying sheet glass etc. | LS | 100000 | |
| Pre-operative Expenses | 50000 | ||
| Total | 6803500 | ||
Machinery and Equipments
Staff and Labour (per month)
Designation |
Nos. |
Salary (Rs.) |
Total (Rs.) |
| Production-cum-Factory Manager | 1 | 20000 | 20000 |
| Administrative officer- cum-Accountant | 1 | 15000 | 15000 |
| Marketing executive | 1 | 18000 | 18000 |
| Production supervisor | 1 | 12000 | 12000 |
| Foreman | 2 | 6000 | 12000 |
| Furnace operator | 1 | 5000 | 5000 |
| Edge working operator | 3 | 3500 | 10500 |
| Glass cutter | 1 | 3500 | 3500 |
| Packing-cum-despatch clerk | 1 | 3500 | 3500 |
| Steno-typist | 1 | 4500 | 4500 |
| Clerk | 1 | 4500 | 4500 |
| Security staff | 2 | 3000 | 3000 |
| Fitters | 3 | 4500 | 13500 |
| Peon | 1 | 3000 | 3000 |
| Factory staff | |||
| Skilled labour | 2 | 4800 | 9600 |
| Unskilled labour | 2 | 3500 | 3500 |
| Total | Total | ||
| + Perquisites @ 22% on salary | 32472 | ||
| Total | 180072 | ||
Raw Materials (per month)
(75% Production in the year)
| Sheet glass 32,000 sq.ft. @ Rs.26 per sq.ft. | 832000 |
| Packing materials LS | 52000 |
| Total | 884000 |
Other Contingent Expenses (per month) |
(Rs.) |
| Postage and stationery | 2000 |
| Telephone expenses | 3000 |
| Consumable stores | 5000 |
| Repairs and maintenance | 10000 |
| Transportation charges | 15000 |
| Advertisement and publicity | 10000 |
| Insurance | 2200 |
| Sales expenses | 15000 |
| Misc. expenses | 3000 |
| Total | 65200 |
Utilities (per month) |
Rs. |
| Power 50,000 kWH units @ Rs.5.00 per unit cost | 250000 |
| Water LS | 10000 |
| Total | 260000 |
| Total Recurring Expenditure (per month) | 1389272 |
| Total Working Capital for 2 Months | 2778544 |
| Land and building | 8210000 |
| Machinery and Equipment | 6803500 |
| Working capital | 2778544 |
| Total | 17792044 |
Machinery Utilization
75% utilisation of machinery and manpower has been taken into consideration.
Financial Analysis
Cost of Production (per year) |
(Rs.) |
| Total recurring cost | 16671264 |
| Depreciation on building @ 5% | 410500 |
| Depreciation on machinery and equipment @ 10% | 470350 |
| Depreciation on Furnace @ 20% | 400000 |
| Interest on investment @13% | 2312966 |
| Depreciation on other equipments and furniture @ 25% | 25000 |
| Total | 20290080 |
Total Capital Investment
For calculation purposes, it is assumed that the unit shall manufacture flat toughened glass of size 5 to 6 mm. the average sale prices of which is taken at Rs.70 per sq.ft. total 3,84,000 sq.ft. (per year), after allowing rejection of 24,000 sq.ft., the saleable quantity will be 3,60,000 sq.ft., @ Rs.60/- per sq.ft.
| Value of Turnover in Rs | 23400000 |
Net Profit (per year)
| Turn over – Cost of production 1 | |
| Total working capital | 3109920 |
Net Profit Ratio
Net profit per year x 100 Turn over per year 13.29 |
Rate of Return
Net profit per year x 100 Total investment 17.48 |
Break-even Point
Fixed Cost (per year) |
(Rs) |
| Depreciation on Furnace @ 20% | 400000 |
| Depreciation on office equipment and furniture | 25000 |
| Depreciation on machinery and equipment | 470350 |
| Depreciation on building | 410500 |
| Interest on total investment | 2312966 |
| Insurance | 26400 |
| 40% of salaries and wages | 864345.6 |
| 40% of other contingent expenses + Utilities (excluding insurance) | 1550400 |
| Total | 6059962 |
B.E.P
FC x 100 FC + NP (per year) 66.09 |
Additional Information
a. Capacity utilisation has been assumed at 75% in the 1st year.
b. The raw materials and sales prices have been taken at the prevailing market and sales prices have been considered ex-factory
- M/s. Associated Erectors (Calcutta)
14 A, S.N. Banerjee Road,
Kolkata-700 013. - M/s. Andrew Yule and Co. Ltd.
Yule House, B. Civil Row,
Kolkata-700 001. - M/s. Punam Machine and Tools
10, Ganesh Chandra Avenue,
Kolkata - 700 013. - M/s. Eastern Engineering Works
7, Fancy Lane, II Floor,
4 A, Courz in House Street, Kolkata - 700 001. - M/s. Supertuf Industries
3/93, DB Gupta Road,
Paharganj, New Delhi.
Raw Material Suppliers
- M/s. Shree Vallabha Glass Works
Vallabha Vildyanagar,
Via Anand, Dist. Kaira, (Gujarat) - M/s. Hindusthan Pilkington
Glass Works Ltd.
Assansol, (West Bengal) - M/s. Triveni Sheet Glass Works Ltd.
Bhurpur, Allahabad (UP). - M/s. Indo Asahi Glass Works Ltd.
Hazaribag, (Bihar) - M/s. Haryana Sheet Glass Works Ltd.
20th Mill Stone,
P. S. Rai, Sonepat,
(Haryana) - M/s. Saraikela Glass Works Ltd.
Kandra, Singhbum, (Bihar)
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
