FLOAT GLASS
[CODE NO 4035
Float glass is a sheet of glass that is manufactured by the use of floating molten glass on a bed of molten metal. This method of manufacturing of float glass gives uniform levels of thickness with very flat surfaces. The modern windows are made from float glass. The process of manufacturing float glass is also known a the Pilkington process as it was manufactured by the British person names Pilkington.
The float glass is the most widely used form of glass in the consumer industry segment. It is known to have high quality and does not require any kind of polishing. It can be shaped easily and bent in various forms. Float glass has a variety of applications such as automobile glass, mirrors, insulated glass, furniture, windows and doors, and others. Various kinds of specialized glass forms such as soundproof glass, laminated glass, toughened glass, frosted glass – all require standard form of processed float glass.
In technical terms, float glass is a smooth, distortion free glass that is used in designing various glass items such as laminated glass, heat toughened glass, so on and so forth. It has a translucent nature and is capable of transmitting about 87% of the incident light. It is known to provide the user with a crystal clear view.
During the process of manufacturing float glass, it is known to be treated and cured well to gain the best of strength and durability. It is known to be more sustainable than plate glass and has the same amount of thickness. It is also known to have incredible amount if density and resilience. The float glass is known to have the ability to regulate indoor temperature y means of keeping the interiors relatively cool during summers and warm during winters.
Many companies are known to manufacture high performance energy efficient glass which is able to reduce bills of home and office areas, thereby conserving the environment. Float glass is normally known to be 100% recyclable as well as non-toxic to ensure that there is no carbon footprint left behind. It is also designed well to be environmental friendly.
Float glass is diversified to create wide variety of glass products with varying thickness, shades and sizes as per customer requirements. Several processing techniques can be undertaken on float glass such as silk screen printing, bending, sandblasting, acid-etching, thermal toughening, acid-etching and others. Float glass is a versatile item that is known to serve the purpose of domestic housing as well as commercial purpose.
Float glass can be used in various creative ways in residential as well as commercial spaces. Float glass serves as the ideal choice for the displaying items. They can be used for countertops, retail shop windows, showroom display cases, and various other uses. The float glass is known to offer a sparkling and brilliant lustre with a crystal clear finish to enhance the overall aesthetic appeal of the considered space. Float glass is widely used for decor for decorating the homes and offices and its applications are numerous.
COST ESTIMATION
Plant Capacity 600 Ton/Day
Land & Building (10,000 sq.mt.) Rs. 6.84 Cr
Plant & Machinery Rs. 122.95 Cr
Working Capital for 2 Months Rs. 38.85 Cr
Total Capital Investment Rs. 184.14 Cr
Rate of Return 42%
Break Even Point 57%
INTRODUCTION
TYPES OF GLASS FROM THE FLOAT PROCESS
KEY PROPERTIES OF FLOAT GLASS:
USES AND APPLICATION
APPLICATION
BUILDING INDUSTRY
COMMERCIAL GLAZING
DISPLAYS
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS OF FLOAT GLASS
FIGURE: GLASS GENERAL PROCESS
1. BATCH MIXING AND PREPARATION
COMPOSITION OF FLOAT GLASS
2. MELTING
A) HEATING
B) PRIMARY MELTING
C) FINING AND HOMOGENISATION
D) CONDITIONING
THE MAIN TYPES OF MELTING FURNACES ARE:
I) REGENERATIVE FURNACES
II) RECUPERATIVE FURNACES
III) OXYFUEL MELTING FURNACES
IV) ELECTRIC FURNACES
V) COMBINED FOSSIL FUEL AND ELECTRIC MELTING FURNACES
VI) DISCONTINUOUS BATCH MELTING FURNACES
VII) SPECIAL FURNACES
3. FORMING PHASE
FIGURE 4: FLOAT GLASS PROCESS
4. FINISHING AND PACKAGING
ANNEALING
TOUGHENING
COATING AND DECORATING
5. QUALITY ASSURANCE
QUALITY CHECKS, AUTOMATIC CUTTING, AND STORAGE
INSPECTION SYSTEM OF GLASS
6. CUTTING TO ORDER
7. MARKING
8. BIS CERTIFICATION MARKING
MARKET POSITION
CONTAINER GLASS INDUSTRY
FLAT GLASS INDUSTRY
FIBER GLASS INDUSTRY
SPECIALTY GLASS INDUSTRY
GROWTH DRIVERS OF THE GLASS INDUSTRY
GREEN BUILDING CONCEPT
REAL ESTATE SECTOR
AUTOMOTIVES INDUSTRY
SOLAR ENERGY GLASS DEMAND
PACKAGING INDUSTRY
GLOBAL PERSPECTIVE
CHALLENGES FACED BY THE GLASS INDUSTRY
1. COST
2. CAPEX
3. COMPETITION
4. AWARENESS OF GLASS AS ECO-FRIENDLY BUILDING MATERIAL
OR PACKAGING SOLUTION
5. PACKING AND LOGISTICS
6. UNFAVORABLE DUTY STRUCTURE
GOVERNMENT SUPPORT
I. MINISTRY OF COMMERCE & INDUSTRY
II. DIPP
III. HEALTH MINISTRY
IV. ENVIRONMENT MINISTRY
CONCESSION ON NATURAL GAS
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF FLOAT GLASS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF SILICA SAND
SUPPLIERS OF SODA ASH
SUPPLIERS OF DOLOMITE POWDER
SUPPLIERS OF FELDSPAR
SUPPLIERS OF CULLETS
CHINA SUPPLIER OF FLOAT GLASS PLANT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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