Glass Processing and Sheet Metal Working (Cap: 1666.667 sq.mt/Day)

GLASS PROCESSING AND SHEET METAL WORKING (CAP: 1666.667 SQ.MT/DAY)

[EIRI/EDPR/4515] J.C.: 2732INR, 2732US$

INTRODUCTION

Glass has evolved from its humble origins to encompass manifold functionalities, unheard of a couple of decades ago. Today, it is a celebrated building material among architects and interior designers, used in various structures such as skywalks, walkways, floorings, etc. Yet, one of the most common misconceptions among people regarding glass is that it breaks easily and when it does so, can lead to serious injuries. And for such concerns exists a product tough enough to resist heavy impact – laminated glass.

If you’re looking for a suitable safety and security glass for the windows of your home, laminated glass may be your best choice. Laminated glass is a layered type of glass with a laminated sheet resting between 2 layers of glass. This laminated sheet is usually made of polyvinyl butyral or PVB and acts as a sort of adhesive to reduce danger in case the glass gets broken. The number of layers can extend up to 9 as well, keeping in mind that every 2 sheets of glass will have a film of PVB between them.

Laminated glass is manufactured by adhering two or more layers of glass together with a flexible PVB interlayer. This takes place through a heat and pressure process in which the chemical bond formed between the glass and PVB interlayer does not merely join them but ‘conjoins’ them to create an entirely new material.

Laminated glass is a special type of safety or security glass that holds together in case of accidents. It is simply made by sandwiching layers of polyvinyl Butyral (PVB) or structural interlayer material in between two or more glass layers. The layers are usually bonded permanently using both mechanical and chemical bonds.⁣⁣

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COST ESTIMATION

Plant Capacity            1666.667 sq.mt/Day  

Land & Building (6000 sq.mt.)    Rs. 7.82 Cr    

Plant & Machinery                    Rs. 3.00 Cr 

Working Capital for 1 Month    Rs. 2.36 Cr 

Total Capital Investment          Rs. 13.60 Cr 

Rate of Return                          40%

Break Even Point                      49%

CONTENTS

INTRODUCTION

TYPES OF SHEET METAL

VIP WORKS WITH A WIDE VARIETY OF SHEET METAL TYPES, BUT HERE ARE THE MOST COMMON:

SHEET METAL THICKNESSES

BELOW ARE THE CONVERSIONS OF GAUGES/THICKNESSES FOR COMMON SHEET METAL TYPES:

ADVANTAGE OF LAMINATED GLASS

USES OF LAMINATED GLASS

APPLICATION OF SHEET METAL

ADVANTAGE OF SHEET METAL

MARKET OVERVIEW OF GLASS

LAMINATED GLASS MARKET

MARKET OVERVIEW OF SHEET METAL

MARKET OF SHEET METAL FABRICATION

GLOBAL MARKET FOR SHEET METAL FABRICATION SERVICES

B.I.S. SPECIFICATION

RAW MATERIALS FOR GLASS PROCESSING

DETAILS OF GLASS PROCESSING

PREPARATION AND SELECTION OF GLASS

GLASS CLEANING

LAMINATING PROCESS

1.) PVB FILM STORAGE AND CUTTING

2.) LAMINATING THE GLASS WITH INTERLAYER

GLASS COMPRESSING

AUTOCLAVE -HIGH TEMPERATURE & PRESSURE TREATMENT

PHASES IN GLASS LAMINATION

TYPES OF METAL FABRICATION PROCESS

TYPES OF METAL FABRICATION PROCESSES

THERMAL CUTTING

MECHANICAL CUTTING

PUNCHING

BENDING

ASSEMBLING

POWDER COATING

SHEET METAL WORKING PROCESS

1. SHEET METAL GRADES AND MATERIALS

2. SHEET METAL THICKNESS AND TYPES

3. THE FORMING PROCESS – BENDING AND ROLL FORMING

COMMON SHEET METAL FORMING PROCESS

1) CURLING

2) BENDING

3) IRONING

4) LASER CUTTING

5) HYDROFORMING

6) PUNCHING

STEPS INVOLVED IN SHEET METAL FABRICATION

1. WORKING WITH BLUEPRINTS

2. FINALIZING DRAWINGS

3. METAL FABRICATION

4. PRODUCT FINISHING

CUTTING

1. CUTTING WITH SHEAR

2. CUTTING WITHOUT SHEAR

BENDING AND FORMING

JOINING

FINISHING

DETAILS OF SHEET METAL FABRICATION

SHEET METAL FABRICATION: CUTTING

SHEET METAL FABRICATION: DEFORMATION

SHEET METAL FABRICATION: ASSEMBLY

PROCESS FLOW CHART FOR SHEET METAL WORKING

MANUFACTURING PROCESS OF SHEET METAL WORKING

(1) CUTTING (SHEAR) PROCESS

(A) CUTTING PROCESS WITH SHEAR

SHEARED EDGE

SUCH CUTTING PROCESSES INCLUDE THE FOLLOWING:

SHEARING

BLANKING

PUNCHING

(2) FORMING PROCESS

SHEET METAL FORMING PROCESSES INCLUDE THE FOLLOWING:

BENDING

BENDING DIAGRAM

NEUTRAL AXIS

SPRINGBACK

PRESS BRAKE (OPEN)

PRESS BRAKE (CLOSED)

V BENDING

WIPE BENDING

DESIGN RULES

BEND RADIUS

(B) SHEET METAL CUTTING WITHOUT SHEARING

LASER BEAM CUTTING

CAPABILITIES

DESIGN RULES

PLASMA CUTTING

WATER JET CUTTING

ROLL FORMING

ROLL FORMING LINE

SPINNING

SPINNING LATHE

DEEP DRAWING

DEEP DRAWING

STRETCH FORMING

(3) JOINING PROCESS

MAINL THREE TYPES OF JOING PROCESS ARE USED

THERE ARE THREE TYPES OF SOLDERING:

1. SOFT SOLDERING:

2. HARD SOLDERING:

3. BRAZING:

(B) WELDING

MAINLY TWO GROUPS OF WELDING ARE USED IN INDUSTRY:

(C) RIVETING

(4) FINISHING PROCESS

SURFACE FINISHING TECHNIQUES

ABRASIVE BLASTING CLEANING

INDUSTRIAL COATINGS

HOT GALVANISING PROCESS

SURFACE PREPARATION

CAUSTIC CLEANING –

PICKLING –

FLUXING –

GALVANIZING

INSPECTION

COATING STRUCTURE

COATING UNIFORMITY

COATING THICKNESS

HOT DIP GALVANIZED BENEFITS

CORROSION RESISTANCE

GALVANIZED COATINGS PROTECT STEEL IN THREE WAYS:

COATING TOUGHNESS

COMPLETE COVERAGE –

RELIABILITY –

SPEED OF APPLICATION –

FASTER CONSTRUCTION –

LOWEST LIFETIME COST

LONG LIFE –

EASE OF INSPECTION –

COMPETITIVE FIRST COST

BARRIER PROTECTION

COATING DEFECT

DE-LAMINATION

DRAINAGE SPIKES

DISTORTION

FLUX INCLUSION

FLAKING

ROUGH SURFACE CONDITION

RUNS

RUST BLEEDING

WELD SPATTER

WELDING BLOWOUTS

WET STORAGE STAIN

DROSS INCLUSIONS

BARE SPOTS

SAND EMBEDDED IN CASTING

TOUCH MARKS

POWDER COATING PROCESS

THE POWDER COATING SYSTEM

A BATCH POWDER COATING SYSTEM:

A CONVEYORIZED POWDER COATING SYSTEM:

COMPONENTS OF POWDER COATING SYSTEM

PRETREATMENT SYSTEM –

AIR COMPRESSOR

POWDER SPRAY SYSTEM

THERE ARE AT EAST THREE TYPES OF ELECTROSTATIC GUNS IN USE:

POWDER COATING BOOTH WITH RECOVERY SYSTEM –

CURING OVEN

MAIN STEPS

MELT, FLOW, GEL, CURE

POWDER COATING GUNS

DRYING AND CURING

ADDRESSES OF RAW MATERIALS SUPPLIERS

SUPPLIERS OF M.S STRIP COILS

SUPPLIERS OF MIG ELECTRODE WIRE

SUPPLIERS OF PACKING MATERIALS

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF POWDER COATING PAINT

SUPPLIERS OF POWDER COATING PAINT

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

SUPPLIERS OF PUNCHING PRESS

SUPPLIERS OF POWER PRESS

SUPPLIERS OF SHEARING MACHINE

SUPPLIERS OF ROLLING MACHINE

SUPPLIERS OF FLYPRESS

SUPPLIERS OF BENDING MACHINE

SUPPLIERS OF MECHANICAL PRESS

SUPPLIERS OF CNC PLASMA CUTTING MACHINE

SUPPLIERS OF WELDING MACHINE

SUPPLIERS OF PROJECTION WELDER

SUPPLIERS OF SEAM WELDING MACHINE

SUPPLIERS OF SPOT WELDING MACHINE

SUPPLIERS OF GAS WELDING EQUIPMENTS

SUPPLIERS OF MIG WELDING MACHINE

SUPPLIERS OF SUBMERGED ARC WELDING EQUIPMENT

SUPPLIERS OF ARC WELDING MACHINE

SUPPLIERS OF EOT CRANES

SUPPLIERS OF D.G. SETS

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF ETP PLANTS

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR CONDITIONING EQUIPMENTS

SUPPLIERS OF AIR COMPRESSOR

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF POWDER COATING MACHINE

SUPPLIERS OF ANODISING PLANT

SUPPLIERS OF HOT DIP GALVANISING PLANT

SUPPLIERS OF ELECTROPLATING PLANT

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

SUPPLIERS OF PAINTING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS

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)