|
Glass Hollow Ware (Mouth Blown Process)
| Product Code |
: |
94119
94131, 94132, 94133
94148, 94158, 94161
94168 and 94174 |
| Quality and Standards
|
: |
IS 1961: 1968 Glass Table
wares.
IS 1945: 1961 Glass Bottle for ink
IS 1994: 1971 Glass container used for fruit preservation
IS 1962 and 1974-Glass Bottle (wine) Glass Shells |
| Uploaded
on |
: |
May
2007 |
Introduction
Hollow Glassware are made from silica
sand and soda ash. Hollow Glassware contribute about 80% of
total glass production. Major variety of hollow glassware
items are given below:-
i. Different size and colours decorative
cylindrical glass bottles
ii. Glass Tumblers
iii. Lemon Set
iv. Wine and bear mug and ice cream cup
v. Jar and jugs in different sizes and colour
vi. Lantern glass and chimney
There are about 19000 varieties of glass,
which are manufactured in India.
Market Potential
Glass Hollow ware such as glass bottles,
table ware, lemon set, tumbler, jar and chimney are being
used since ancient times. These items have a great demand
due to frequent use and regular breakage. Glassware are very
much useful and essential for storage and packing of wine,
food and chemicals etc. Demand of glass containers is increasing
consistently. Glass containers are widely used in every household.
Basis and Presumptions
i. It has been taken into consideration
that the unit will work on three shift basis for 300 days
in a year.
ii. Production capacity-1st year 60%, 2nd year 70%, 3rd year
onwards 80%.
iii. Labour and wages mentioned as per the prescribed Minimum
Wages Act.
iv. Interest rate at 13% per annum
v. Margin money-25%
vi. Operative period of the project is about 10 years.
vii. The cost of land, construction charges, machinery and
equipment, raw materials, and consumables, salaries and wages,
other expenditure etc. indicated in the profile are based
on the prices prevailing at the time of preparation. Therefore,
they are subject to necessary changes from time to time based
on the local condition.
viii. One time cullet would be used at the start of the furnace
for melting. Cullet is produced there after during the regular
melting and shaping process in the glass unit.
Implementation Schedule
| Sl. No. |
Activity |
Period
(in months) |
| 1. |
Land acquisition |
2 |
| 2. |
Building construction
|
8 |
| 3. |
Purchase of machines
|
14 |
| 4. |
Installation of machines
|
15 |
| 5. |
Trial Production |
16 |
| 6. |
Commercial Production
|
18 |
Technical Aspects
Process of Manufacture
Glass hollow ware are manufactured by
mouth blown or semi automatic process as given below:
a) Preparation of Batch
Different raw materials are weighed in
proportion and mixed in mixer. Cullet glass are mixed in the
above mixer and fed into the glass furnace.
b) Melting of Batch
The batch is fed in the furnace and melted
at temp. 1400-1500ºC.
c) Shaping with Molten Glass
Molten glass is shaped by Mouth Blown
Process. Molten glass (Gob) is taken out from furnace with
the help of cast iron rods and blown, more glass is gathered
and blown/pressed in the desired mould made of wood or metal.
These glassware are sent for annealing
in the annealing chamber or leher to remove strains. Annealing
is a process of slow cooling of glassware. The glassware are
sorted and sent for packing.
Quality Control and Standards
BIS has published the following standard
specifications for Hollow Glass ware:
Hollow Glass Ware
| IS 1961:1968 |
Glass Table ware |
| IS 1945:1961 |
Glass Bottle for ink
|
| IS 1994:1971 |
Glass container used
for fruit preservation |
| IS 1962 and 1974 |
Glass Bottle (wine) |
Financial Aspects
A Fixed Capital
| (i) Land |
App. Cost. (Rs.) |
| About 2000 sq. m. land
will be required for the project |
4000000 |
(ii) Building
| Particulars |
Size |
Area sq. m. |
Rate (Rs./ Sq.M.) |
Cost (Rs.) |
| Workshed |
50×10 |
500 sq. m. |
3000
|
1500000
|
| Office |
10×5 |
50 sq. m. |
4000
|
200000
|
| Godown |
10×10 |
100 sq. m. |
3000
|
300000
|
| Laboratory |
5×5 |
25 sq. m. |
5000
|
125000
|
| Boundary Wall |
|
|
LS
|
130000
|
| Factory Gate and Watchman
room |
|
|
LS
|
105000
|
|
Total
|
2360000
|
(iii) Machinery and Equipments
| Particulars |
Indig-enous/ Imported
|
Nos. |
Cost (Rs.) |
| Oil Fired Tank Furnace
5 MT |
Indigenous |
1 |
3000000
|
| Chimney |
“ |
1 |
200000 |
| Anealing Lehr 4' x 75'
fitted with heater and Motor 40 HP |
“ |
1 |
320000 |
| Compressor 50 HP |
“ |
1 |
300000 |
| Vacuum Pump |
“ |
1 |
90000 |
| Moulds and Dies LS |
“ |
- |
50000 |
| Automatic batch mixer
5 HP |
“ |
1 |
40000 |
| Screening machine with
1 HP motor |
“ |
1 |
25000 |
| Magnetic Separator |
“ |
1 |
25000 |
| Weighing machine |
“ |
1 |
25000 |
| Oil tank storage capacity
50,000 litres |
“ |
1 |
15000 |
| Rotary pump for furnace
|
“ |
2 |
200000 |
| Lathe machine 6' |
“ |
1 |
30000 |
| Drill machine |
“ |
1 |
25000 |
| Bench grinder 9"
|
“ |
1 |
8000 |
| Testing equipments |
“ |
LS |
12000 |
|
Total
|
4365000
|
| Electrification
and installation of machines and equipments @22 % |
960300
|
| Transformer
|
96000 |
| Furniture
and fixture of office block |
40000 |
|
Total(ii)
|
5461300
|
| (iii) Pre-operative
Expenses |
90000 |
| Total
Fixed Capital (i)+(ii)+(iii) |
7911300
|
B. Working Capital (per month)
(i) Personnel
| Designation |
Nos. |
Salary / month |
Total (Rs.) |
| Manager |
1 |
12000
|
12000
|
| Glass Technologist |
1 |
14000
|
14000
|
| Foreman |
2 |
7000
|
14000
|
| Supervisor |
6 |
7000
|
42000
|
| Accountant |
1 |
6000
|
6000
|
| Clerk |
2 |
4000
|
20000
|
| Storekeeper |
1 |
4000
|
4000
|
| Skilled worker |
24 |
4000
|
96000
|
| Un-skilled worker |
22 |
4000
|
88000
|
| Peon cum watchmen |
4 |
3000
|
12000
|
| Sweeper |
1 |
3000
|
3000
|
|
Total
|
311000
|
| +22% perquisites
|
68420
|
|
Total
|
379420
|
(ii) Raw Materials (per month)
| Description |
Qty. |
Rate (Rs.) |
Amount (Rs.) |
| Glass batch (Silica sand,
soda ash and decoloriser |
200MT |
28000
|
560000 |
| Cullet Glass |
100MT |
1900/Mt
|
190000
|
| Furnace Oil |
50000L |
25/ltr.
|
1250000
|
| Packing material |
L.S. |
|
60000 |
|
Total
|
2060000
|
| (iii) Utilities (per
month) |
| Electricity |
80 H.P.×0.73×0.8×8×25×4
|
37376 |
| Water |
L.S. |
3000 |
|
Total
|
40376
|
| (iv) Other Contingent
Expenses (per month) |
(Rs.) |
| Postage and Stationery
|
2000
|
| Telephone |
2000
|
| Repair and Maintenance
|
4000
|
| Transportation charges
|
10000
|
| Sales expenses |
10000
|
| Misc. Expenditure |
10000
|
|
Total
|
38000
|
| (v) Total Recurring
Expenditure (per month) |
(Rs.) |
| Salaries and wages |
379420
|
| Raw materials |
2060000
|
| Utilities |
40376
|
| Other Contingent expenses
|
38000
|
|
Total
|
2517796
|
| (vi) Total Working Capital
(on 2 months basis) |
5035592
|
C. Total Capital Investment
| Total fixed investment
|
7911300
|
| Total working capital
|
5035592
|
|
Total
|
12946892
|
Financial Analysis
| (1) Cost of Production
(per annum) |
(Rs.) |
| Total recurring cost
|
30213552
|
| Depreciation on building
@ 5% |
118000
|
| Depreciation on machinery
and equipment @ 10% |
242130
|
| Depreciation on furniture
and fixtures @ 20% |
8000
|
| Interest on total investment
@ 13% |
1683095.96
|
| Depreciation on furnace
@ 20% |
600000
|
|
Total
|
32864778
|
| (2) Sales (per year)
|
(Rs.) |
| 2400 M.T. Hollow glasswares
@ 15000 M.T. |
36000000
|
| (3) Net Profit (per
year) |
= |
Sales – cost of production
|
| |
= |
36000000 – 32864778
|
| |
= |
3135222
|
| |
|
|
| (4) Net Profit Ratio
|
= |
Net profit per year X
100
-------------------- |
| |
|
Sales per year |
| |
|
|
| |
= |
3135222x 100
---------------
|
| |
|
36000000
|
| |
|
|
| |
= |
8.71
|
| |
|
|
| (5) Rate of Return |
= |
Net Profit per year x
100
--------------------------- |
| |
|
Total Investment |
| |
|
|
| |
= |
3135222x 100
----------------------
|
| |
|
12946892
|
| |
|
|
| |
= |
24.22
|
(6) Break-even Point
| (i) Fixed Cost |
(Rs.) |
| Depreciation on Building
|
118000
|
| Depreciation on machines
and Equipment |
242130
|
| Depreciation on furniture,
fixture and minerals |
8000
|
| Depreciation on Furnace
|
600000
|
| Installation Investment
interest @ 13% |
1683095.96
|
| 40% of salary and wages
|
1821216
|
| 40% of other Contingent
expenses |
182400
|
|
Total
|
4654842
|
| B.E.P |
= |
Fixed Cost × 100
-----------------------
|
| |
|
Fixed cost + Net Profit
|
| |
|
|
| |
= |
4654842 × 100
-----------------------
|
| |
|
4654842 +3135222
|
| |
|
|
| |
= |
|
| |
|
0
|
| |
|
|
| |
= |
59.75
|
Addresses of Machinery Suppliers
1. M/s. Import India Ltd.
13-19, Gorva Industrial Estate,
Vadodra, (Gujarat)
2. M/s. Alock and Co. (P) Ltd.
7, Hasting Street,
Kolkata-700001.
3. M/s. Saini Ltd.
Vadodara
(Gujarat).
4. M/s. Glass Equipments (India) Ltd.
Bahadurgarh
(Haryana)
5. M/s. Allied Research and Engineering (Pvt.) Ltd.
Sangli, (Maharashtra)
Raw Material Suppliers
1. M/s. Raj Kamal Silica Works
P.O. Shankergarh,
Distt. Allahabad.
2. M/s. Ajmer Mineral Grinding Corporation
Ajmer, (Rajasthan)
3. M/s. Pioneer Chemicals Co.
Tilak Market, Sadar Bazar,
Delhi-110006.
4. M/s. Standard Minerals
8, S, Deviji Street,
Mumbai-40003.
Borax
1. M/s. Borax Morarji Co. Ltd.
Mahatma Gandhi Road,
Ambernath, Distt. Thane
(Maharashtra)
Soda Ash
1. M/s. Tata Chemicals
Meethapur (Gujarat)
2. M/s. Sahn Chemicals Works
Sahanpur, Varanasi.
Refractories
1. M/s. Belpahar Refractories Ltd.
48, Chaurayee Road,
Kolkata.
2. M/s. Carborundum Universal Ltd.
11/12, North Bitch Road,
Chennai.
3 M/s. Orissa Industries Ltd.
P.O. Narang Distt.
Cuttack (Orissa)
4. M/s. Kumar Dubhi Fire Clay and
Silica Works
P.O. Kumar Dubhi,
Distt. Dhanbad.
Contact for more information:
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
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