|
Laminated Safety Glass
| Product Code |
: |
94105 |
| Quality and Standards
|
: |
IS 2553:1971
IS 6480:1971
IS 6640:1972
IS 2533:1976 |
| Production Capacity |
: |
Quantity: 13,800 Sq.mtrs.
Value : Rs. 6817200 |
| Uploaded
on |
: |
June
2007 |
Introduction
Laminated safety glass has good industrial
potential due to its multiple advantages in commercial and
industrial applications though the product is not as popular
as toughened glass. The main applications of laminated safety
glass are:
i. Automobiles,
ii. Railways,
iii. Marine vessels,
iv. Aircrafts,
v. Defence,
vi. Household construction applications, and
vii. Other industrial applications.
The main advantages of laminated safety
glass are:
i. On accidents the glass does not harm/injure
the body,
ii. It acts as a good insulator,
iii. It is sound proof, and
iv. It has got a good strength compared to toughened and other
sheet glasses.
Laminated safety glass is a sandwich made
up of a PVC interlayer or interlayers adhered between two
glass sheets. Laminated glass is more resistant to fracture
than monolithic glass, but in case of fracture, the PVC interlayer
holds the fragments in place.
Market Potential
There is a very good demand for setting
up this product in small scale sector, in commercial and industrial
applications. The main consumer of these products are Railways,
Automobiles, Defence, Aircrafts, Marine vessels and in domestic
applications. The growth of laminated safety glass industry
depends upon the development of automobile industry and also
in construction of multi-storeyed buildings. As the automobile
industry is steadily growing, the demand for laminated safety
glass is also increasing. Besides this, there is considerable
demand for laminated safety glass as spares for replacement
purposes. Therefore, there is good scope for setting up new
units.
Basis and Presumptions
i. The production capacity of the unit
has been worked out on the basis of single shift basis of
8 hours per day for 300 working days in a year.
ii. The unit is capable of manufacturing the laminated safety
glass sheets in different shapes, sizes and thickness.
iii. The costs of machinery, equipments and raw materials
are as prevailing at the time of preparation of this report.
iv. The wages proposed in the profile as per the prevailing
wage practice.
v. The rate of interest of 13% is considered both for recurring
and non-recurring investment.
vi. Margin money is generally about 25%, however, this varies
according to the type of entrepreneur.
vii. Operative period of the project is around 12 years considering
technology obsolescence rate and period of repayment of loan.
viii. To achieve full plant capacity 1 to 2 months trial production
is required.
Implementation Schedule
| Sl. No. |
Activity |
Period
(in months) |
| 1. |
Survey for collection
of data in respect of demand, raw material including power
availability and technology |
0 to 1 month |
| 2. |
Arrangement for margin
money |
1 to 2 month |
| 3. |
Preparation of project
document and registration |
1 to 2 month |
| 4. |
Financial assistance
|
3 to 4 month |
| 5. |
Selection of rented premises
|
3 to 4 month |
| 6. |
Electricity and water
- tie up for availability |
4 to 5 month |
| 7. |
Construction/selection
of machinery |
4 to 6 month |
| 8. |
Placement of order (machine)
|
5th month |
| 9. |
Erection and commissioning
|
7th month |
| 10. |
Recruitment of staff
and labour |
6 to 7th month |
| 11. |
Procurement of raw materials
|
7th month |
| 12. |
Trial run/modification
|
8th month |
From inception to implementation of the
project, it will take approximately eight months.
Technical Aspects
Process of Manufacture
The raw materials for manufacturing the
laminated safety glass are ordinary sheet glass/float glass
and PVC sheet. Sheet glass/float glass suitable for this product
should be of good quality i.e. free from stone, weariness,
stresses, strains, scratches and other surface defects. The
important stages in the manufacture of laminated sheet glass
are:
i. Raw glass sheet inspection
ii. Glass cutting
iii. Glass washing
iv. PVC interlayer cutting
v. Preparing the resin
vi. Assembly of sheet glass and interlayer
vii. Pouring resin on each side of the PVC between it and
the glass
viii. Rolling and pressing
ix. Drying
x. Edge finishing
xi. Final inspection
xii. Packing
Quality Control and Standards
Quality Control and Standards Generally
quality product should be free from defects and foreign materials
which creates problems when it is in use. These defects can
be controlled at every stage of the operations of the process
by thorough checking, right from raw materials selection to
finished products and packing. The relevant Bureau of Indian
Standards are as follows:
| IS 2553:1971 |
Safety glasses |
| IS 6480:1971 |
Toughened safety glass
for ship side scuttles |
| IS 6640:1972 |
Toughened safety glass
for windows |
| IS 2533:1976 |
Safety glass (Second
revision) with amendments No. 1 and 2 and reaffirmed in
1976 |
Production Capacity
(per annum)
Clay-Graphite Crucibles of different sizes
upto No. 500
| Quantity |
: 13, 800 sq.mtrs. of
Laminated safety glass |
| Value |
: 6817200 |
Pollution Control
The product does not create any noise
or water pollution. The air pollution will have to be continuously
monitored.
Energy Conservation
Not applicable as far as fuel is concerned.
Simple precautions and knowledge of effective utilisation
of electric power is necessary.
Financial Aspects
A Fixed Capital
| ( i ) Land and Building
|
(Rs.) |
| Land 200 Sq. M @ Rs 3000
/Sq.m |
600000 |
| Build up area 200 sq
mtr @ 5000 /sq mtr |
1000000 |
|
Total
|
1600000 |
(ii) Machinery and Equipments
| Description |
Qty. (Nos.) |
Amount (Rs.) |
| Glass washing and drying
machine with blower |
1 |
35000 |
| Hand operated glass lamination
machine with accessories |
1 |
190000 |
| Edge cutting and finishing
machine |
2 |
80000 |
| Glass cutting machine
with arm table cutting rail and swivel cutting head (for
shaping) |
1 |
80000 |
| Racks for raw sheet glass
|
LS |
15000 |
| Electric oven size 8
× 8 × 8 with fan and temp. indicator |
1 |
70000 |
| Working tables |
4 |
20000 |
| Misc. equipments, grinding
wheels, tools, balance, diamond cutter, electric stove
etc. |
30000 |
| Office furniture |
50000 |
| Electrification and installation
charges @ 10% |
57000
|
|
Total
|
627000
|
| (iii) Pre-operative Expenses/
Project Cost and Nonrefundable Deposits etc. |
40000 |
|
Total
|
667000
|
B. Working Capital (Per Month)
( i ) Personnel (per month)
| Designation |
No. |
Salary month (Rs.)
|
Total (Rs.) |
| Production Supervisor
|
1 |
10000 |
10000 |
| Cashier-cum-Accountant
|
1 |
6000 |
6000 |
| Skilled workers |
2 |
5000 |
10000 |
| Un-skilled workers |
4 |
3500 |
14000 |
| Peon |
1 |
3000 |
3000 |
| Watchman |
2 |
3000 |
6000 |
|
Total
|
49000 |
| + 22% perquisites
|
10780 |
|
Total
|
59780 |
(ii) Raw Materials (per month)
| Particulars |
Qty. |
Rate (Rs.) |
Value (Rs.) |
| 3 mm thickness sheet
float glass |
2500 sq.mtrs. |
140 per sq.mtr. |
350000
|
| PVC sheet |
1250 mtrs. |
40/mtr. |
50000
|
| Lamination chemicals
|
LS |
|
20000 |
| Packing materials |
LS |
|
5000 |
|
Total
|
425000
|
| (iii) Utilities (per
month) |
(Rs.) |
| Power 1125 kWH @ Rs.5/unit
|
5625
|
| Water |
500 |
|
Total
|
6125
|
| (iv) Other Contingent
Expenses (per month) |
(Rs.) |
| Postage and stationery
|
1500 |
| Telephone |
2000 |
| Consumable stores |
2000 |
| Repairs and maintenance
|
2000 |
| Transport and conveyance
|
5000 |
| Advertisement and publicity
|
5000 |
| Insurance |
2000 |
| Other unforeseen expenses
|
2000 |
|
Total
|
21500 |
| (v) Total Recurring
Expenditure (per month) |
(Rs.) |
| Personnel |
59780 |
| Raw materials |
425000 |
| Utilities |
6125 |
| Other contingent expenses
|
21500 |
|
Total
|
512405 |
| (vi) Working Capital
(for 2months ) |
1024810 |
C. Total Capital Investment
| Fixed capital |
2267000 |
| Working capital for 2
months |
1024810 |
|
Total
|
3291810 |
Financial Analysis
| (1) Cost of Production
(per annum) |
(Rs.) |
| Total recurring expenditure
|
6148860 |
| Depreciation in Building
@ 5 % |
80000 |
| Depreciation on furniture
@ 20% |
10000 |
| Depreciation on machinery
@ 10% |
57700 |
| Interest on total capital
investment @ 13% |
427935 |
|
Total
|
6724495 |
| (2) Turnover (per
annum) |
(Rs.) |
| Sale of 13,800 sq.mtr.
of laminated safety glass @ Rs.590 sq.mtr. (after allowing
5% rejection) |
8142000 |
|
Total
|
8142000 |
| (3) Net Profit (per
year) |
= |
Turn over – Cost of production
|
| |
= |
Rs. 8142000– 6724495
|
| |
= |
1417505 |
| |
|
|
| (4) Net Profit Ratio
|
= |
Net profit x 100
-------------------- |
| |
|
Turnover |
| |
|
|
| |
= |
1417505*100
------------------ |
| |
|
8142000 |
| |
|
|
| |
= |
17.41 |
| |
|
|
| (5) Rate of Return |
= |
Net profit x 100
--------------------------- |
| |
|
Total investment |
| |
|
|
| |
= |
1417505x 100
---------------------- |
| |
|
3291810 |
| |
|
|
| |
= |
43.06 |
(6) Break-even Point
| Fixed Cost |
(Rs.) |
| Depreciation on Building
@ 5 % |
80000
|
| Depreciation on machinery
|
57700 |
| Depreciation on furniture
|
10000 |
| Interest on total capital
investment |
427935 |
| 40% of salaries |
51744 |
| 40% of other contingent
expenditure (excluding insurance) |
93600 |
| Insurance |
24000 |
|
Total
|
744979 |
| B.E.P |
= |
Fixed Cost × 100
----------------------- |
| |
|
Fixed cost + Net Profit
|
| |
|
|
| |
= |
744979 x 100
----------------------- |
| |
|
744979 +1417505 |
| |
|
|
| |
= |
34.45% |
Addresses of Machinery and Equipment
Suppliers
1. M/s. Wessmake Industrial Products
B-104, Mayapuri, Phase-I,
New Delhi-64.
2. M/s. Mansfield Conveyors (P) Ltd.
S-77, Baddi Indl. Estate,
Delhi-42.
3. M/s. Wildbar Field (India) Ltd.
Mohur Street Building, 25-A,
Dr. Annie Besant Road,
Mumbai-18.
Raw Material Suppliers
1. M/s. Sri Jagadamba Plywoods
33/1, BVK Iyengar Road,
Bangalore-53.
2. M/s. A.S. Glass and Plywoods
8, Mysore Road, New Tharagupet,
Bangalore-2.
3. M/s. Dhariwal Glass
58, 2nd Floor, 21,
Killari Road,
Opp. T.V. Complex,
Bangalore-53.
4. M/s. Mahaveer Glass House
32, BVK Iyengar Road,
Bangalore-53.
5. M/s. Rachana Enterprises
69/1, 2nd Main,
8th Block, Jayanagar,
Bangalore-82.
6. M/s. Deepak Enterprises
39B, Mamulpet,
Bangalore-53.
Contact for more information:
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
|
