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The basic idea of putting-up this project was to manufacture Glass Lens of Automotive Headlamps to meet captive requirement of a Large Head Lamp manufacturing unit and cater to domestic demand of this product. 

The project envisages the use of soda lime glass made out of high grade raw materials abundantly available in Rajasthan (India). The project is planned to manufacture Automotive Head Lamp Glass Lenses equivalent to any European glass manufacturer. The quality of the glass lens shall be meeting the European standards (‘E’ Mark) as per E.C.E. regulations.

Besides Glass Lenses following products can also be manufactured by the same machinery :-

1.                 Street Lighting Covers (Diffusers)

2.                 Barium Crystal Glassware.

3.                 Giftware

4.                 Perfumery Bottles.

The project envisages the following criteria and selection of equipments: -

·                     To house initially a small capacity soda lime melting Furnace of maximum 7 tons per day conforming to European quality standards and sufficient provision in the land and buildings & Batch House for expansions upto 50-60 tons per day.

·                     Mixed melt design furnace using HSD / LSHS Fuel augmented by electric boosting using molybdenum electrodes, designed and supplied by M/s. FIC (UK) LTD.

·                     Special type of Electrocast Refractories at the glass contact areas.

·                     Perfect level of glass in the gathering forebays using world renowned “ZIPPE” glass level controller.

·                     Deploying Robot for gathering the glass to maintain the efficiency and repeatability of size and weight of the Gobs.

·                     Automatic CNC Hydraulic multi-station presses monitored by digital electronic circuits for programming and execution.

·                     Automatic takeout mechanisms using vacuum pick-up pads.

·                     Special type of multi-zone longer annealing lehr to relieve stresses in the glass after pressing.

·                     Strict quality control measures supported by the State-of-Art equipments at every stage.

·                     Automation in the batch mixing process by equipments to sort the raw materials, stored in the bins, accurate weighing of all the constituents of the Batch by Electronic Load Cells, Mixing in a special Batch Mixer, conveying the mixed Batch to Furnace and charging the Furnace continuously and proportionately to the draw of Molten Glass.

LOCATION :

The project is located at RIICO Industrial Area, Bindayaka. 12 Km, from Jaipur city on Sewar Road. It is well connected with National Highway, Railway, Airport and also dry Port at Jaipur [I.C.D] to facilitate Export consignments.

LAND AND BUILDING :

Total area of the land is 21794 Sq. Meter total covered area of  building is 3300 Sq. Meter which is sufficient to have expansion in capacity from the existing 7 MT per day to 20 MT per day.

POWER :

11/33 KVA H.T. Power constantly available from the Rajasthan State Electricity Board Sub-Station. Planning was to have a direct cable / feeder line from the Sub-Station to factory's 750 KVA Transformer. This is backed-up by Diesel Generating Set of 750 KVA capacity. There is provision for un-interrupted power supply (UPS) for vital electronic equipments and control systems.

WATER :

Constant supply of water from own Borewell backed up by RIICO Tube Well across the Road. Provision for water treatment plant to feed soft water for production machines like Glass Gathering Robot & Furnace Heating Electrodes. Water is available in plenty in the area.

FUEL :

Constant availability of fuel by provision of HSD storage tank and LPG storage yard with 20 KL tank.

COMPRESSED AIR :

Best quality compressors with stand by arrangements to provide necessary moisture free air for combustion and for other production equipments and services.

MOULD REPAIR SHOP :

Mould repair & general maintenance shop with hard chrome plating facility.

LIST OF EQUIPMENTS & INFRASTRUCTURE :

MAIN EQUIPMENTS :

(A)     Available on Site :

1.                GLASS MELTING FURNACE :-

The furnace is procured from M/s. FIC (UK) Ltd., who are world renowned technology supplier & manufacturer of Glass Melting Furnace. The Furnace is oil fired, electrically boosted with distributors & required forebays. Major specifications are :- 

Furnace Capacity              :               7 MT/24 hours

Fuel                                    :               Light Diesel oil, Electricity and LPG

Energy consumption          :              2850 Kcal/ per Kg. of Glass

Furnace design                   :              Cross Fired oil burning with electrical

boost for melting of Glass and arrangement of necessary distributors and required Forebays.

 Forebays                            :              One    electrically    heated   gathering

bay suitable for ball Gatherer with stirrer.

One Gas heated gathering bay for manual gathering with 3 working holes. Provisions for a third forebay.

The complete furnace, distributor and gathering bays consist of the following main  equipment :-

I)             Batch Charger

II)          Combustion equipment

III)       Hot Spot boost

IV)       Automatic Glass level controller

V)          Gathering bay (Gas fired)

VI)       Gathering bay (electrically heated)

VII)    Thermo couples – in glass type

VIII) Thermo couples – atmospheric type

IX)       Spare parts

2.                 ROBOT FOR GATHERING GLASS :

Robot Equipment for gathering glass has been  purchased from M/s. Amav GmbH, Germany who have also provided the Technical Know-how for Glass production.

Robot Gathering Machine (Model KSEM-IV)

In 5-axis version. 4-axis to position the ball in the space and 1 additional axis (K-axis). Machine is CNC controlled with accessories and spare parts.

Maximum gathering weight is upto 10 Kg with tolerance + 1%.

3.       CNC 8-station Glass press (Model MHP 10-8/1500), Purchased from M/s. AMAV GmbH, Germany

Table diameter – 1500 mm

Electrical indexing with accessories and spare parts. 

4.      Glass scissor for gob cutting (Pneumatic driven), Purchased

from M/s. AMAV GmbH, Germany. 

5.       CNC controlled Automatic takeout unit with vacuum pump.

            Having adjustable vertical and horizontal axis with spare parts.

            Purchased from M/s. AMAV GmbH, Germany

6.                 Batch House with Phillips Automatic Weighing System.

Batch house has been supplied and erected by M/s. Fabrocon, Baroda who are leading company in this field. It is an automatic batch house with capacity of 20 Tonnes / day to sort out raw materials, storing in bins, accurate weighing of all batch constituents by electronic load cells of Phillips, mixing in a special batch mixer, conveying the mixed batch to furnace and charging  the furnace continuously.

The batch house unit consists of following sub systems :

1.                  Sand System

2.                  Cullet System

3.                  Other raw material system

4.                  Storage of raw material & de-dusting

5.                  Dosing weighing & mixing

6.                  Batch transportation to hopper with DOG House

B)               To be Procured :

1.                 Automatic (Geneva Gear Mech.) Hydraulic Press – 02 Nos.

2.                 Steel Structure & Glass Refractory for Furnace Hand Press – 02 Nos.

3.                 Annealing Lehr (8 Zones, 24 M Long).

OTHER SERVICES TO BE INSTALLED :

1.                 750 KVA Transformer with OLTC.

2.                 D.G. Sets (380 KVA) – 03 Nos.

3.                 Compressors ( 150 CFT / Min) – 02 Nos.

4.                 LPG & HSD Storage Tanks and Pipelines.

RAW MATERIAL :

Best quality of Raw materials and minerals required for Glass manufacturing are available in Rajasthan , which are being supplied to all major Glass Units. The raw materials required for our composition of Glass used for Lens manufacturing are sand, Soda ash, Line, Borex etc.

CAPACITY :

The present installed capacity is 7 MT per day. total installed capacity per annum will be 2450 MT considering 75% capacity utilization the plant, will be able to produce 1800 MT of  Glass per annum in different product mix with various sizes and shapes.

SCOPE OF MARKET :

A)               For Glass Lenses :

The requirement  of Automotive Head Lamp Lens in the country is huge. The country’s demand can be served upto 30 to 40% of total demand, ensuring the full capacity utilization right from start. This gives ample opportunity to expand further to meet the country’s demand as well as the export possibilities as the cost of manufacture is comparatively much lower. At present cost of imported lenses is approximately Rs. 100 per Kg. Exclusive of Import Duty. At present there is no such plant in India dedicated for Automotive Head Lamp Lens manufacturing and which can provide low alkalinity Glass quality Lens.

Present demand of Indian manufacturers for Head Lamp Glass Lenses is being met mainly through imports and partly from domestic producers who are using crude manual processes leading to inferior quality glass lenses. Due to much higher cost of Import glass lenses, most Indian companies are using high alkalinity glass produced by local manufacturers. Since this plant shall be offering low alkalinity good quality glass lenses at comparatively low prices, it can be confident to catch major market share in this field.

With increase in Global production of all category of vehicles, the demand for Automotive Head Lamps is also constantly increasing leading to increase in demand of Glass Lenses. Hence the product has very good market potential.  

B)        For Other Products :-

Barium Crystal Glassware are highly demanded product now-a-days having applications in hotel industry and house hold besides vast potential of export market. Likewise perfumery bottles & street lighting covers are having very high market potential.         

COST OF GLASS :  

The cost of manufacture of Glass is derived taking into the account of the input cost of raw materials, fuel, electricity, salaries & wages and fixed cost including depreciation & Furnace rebuilding liability per year leaving ample scope of profits and high return of investment even on very competitive global selling price.

Good profits and reasonable return on investment can be earned by fixing the selling price at a very attractive and highly competitive price.

PRESENT STATUS OF PROJECT :

The mother Company has already invested Rs. 7.50 Crores. Presently the main Building, Service Building, Automatic Batch House are complete and ready for use. Furnace equipments, Robot Gathering and Automatic Hydraulic Press are already at site.

The details of investment against total project cost are as under :-

Total Project Cost:                                                                          (Fig are in Indian Rupees in Lacs)*

PROFITABILITY STATEMENT