Detailed Project Report on toughened glass plant

TOUGHENED GLASS PLANT
[CODE NO.3138]


Toughened or tempered glass is a type of safety glass processed by controlled thermal or chemical treatments to increase its strength compared with normal glass. Tempering puts the outer surfaces into compression and the inner surfaces into tension. Such stresses cause the glass, when broken, to crumble into small granular chunks instead of splintering into jagged shards as plate glass (a.k.a. annealed glass) creates. The granular chunks are less likely to cause injury.

As a result of its safety and strength, toughened glass is used in a variety of demanding applications,including passenger vehicle windows, shower doors, architectural glass doors and tables, refrigerator trays,mobile screen protectors, as a component of bulletproof glass, for diving masks, and various types of plates and cookware.

Toughened glass, as the name itself suggests, is glass material is tougher than ordinary glass that has low resistance power. These are stronger varieties that are used in various places, whether residential or commercial constructions. In fact, the strength of the toughened glass is up to five times more than that of annealed glasses. Toughened glass is also used to manufacture glassware and these products are comparatively safer and offer more durability. However, the strength of these items should not be confused with any wrong perception of being unbreakable. If products made of toughened glass are handled with proper care, they can last even for a lifetime.

Annealed glass is heated above 720°C, which is the highest annealing point and after the extreme heating procedure, rapid cooling is conducted with air. Taking the surface lower than the annealing point cools off the glass. This causes the surface to become hard and contracts while the core still flows for a while.

Finally, the core cools into numerous layers under tensile stress, balanced by compressive surface stresses.

Because of these stresses, the toughened glass is strong and tough. However, a scratch on the surface or even a small cheap can weaken the layer and sometimes it may lead to breaking into small pieces.

There is an alternative process of creating toughened glass, which is done by using certain chemicals. Here the surface layer of the glass needs to be forced at least 0.1mm thick into compression by the exchange of sodium ions in the surface of the glass with the potassium ions that are larger by 30%, by immersing the glass into a molten potassium nitrate mixture. This chemical process of making toughened glass results in more toughness.  This process of manufacturing can be used with complex shaped glass objects.

Toughened glass items have wide usage. Where the chances of damage and stress are high, this glass variety is used. Typical usages of this glass include counter tops, shelves, glass table tops, doors, window panels, window glazing, etc. Therefore, it is suitable for use in residential and commercial purposes.

Toughened glass is a type of soda-lime-silica glass with a sheet thickness 4-12 mm.  The sheet has a central tensile stress of 500-1200 kg/cm2 and a ratio of surface compressive stress to central tensile stress of 2:1 to 4:1. The article is toughened by heat exchange with an oil (or chilled air) in which these is maintained from 0.01 - 0.07 % liquid. The boiling point liquid may be an organic liquid such as carbon tetrachloride, methanol, benzene, toluene, trim ethyl alcohol, ethyl alcohol or Xylene etc.

The toughened glass is described as a type of glass which has been mechanically strengthen by a thermal process in which a layer of compression has been introduced at the surface.


COST ESTIMATION

Plant  Capacity                                :       1500.00 Sq.ft./day                               
Land & Building (20000 Sq.Ft)    :    Rs. 25.00 Lacs
Plant & Machinery                          :    Rs. 1.20 Cr
Working Capital for 2 Months      :    Rs. 93.22 Lacs
Total Capital Investment              :    Rs. 2.61  Cr
Rate of Return                               :    46%
Break Even Point                          :    53%


INTRODUCTION    
LAMINATED TOUGHENED SAFETY GLASS:-    
TOUGHENED GLASS HAS TO PASS THE FOLLOWING IMPORTANT TESTS:    
BECAUSE OF THE STRENGTH AND OTHER SPECIFIC PHYSICAL PROPERTIES
MENTIONED ABOVE, IT FINDS APPLICATIONS IN THE FOLLOWING FIELDS:    
ADVANTAGES AND DISADVANTAGE OF TOUGHENED GLASS    
AUTOMOBILES    
BUILDINGS AND STRUCTURES    
FOOD SERVICE    
COOKING AND BAKING    
MOBILE DEVICES    
MANUFACTURING    
ADVANTAGES    
DISADVANTAGES    
INSULATED GLASS    
MARKET POTENTIAL    
UK TEMPERED GLASS MARKET DEMAND, BY APPLICATION, 2012-2022
(MILLION SQUARE METERS)    
OVERVIEW OF GLOBAL GLASS MARKET    
MAIN TYPES OF GLASS    
ANNEALED GLASS    
TOUGHENED GLASS    
LAMINATED GLASS    
LAMINATED GLASS IS PRODUCED USING ONE OF TWO METHODS:    
COATED    
DETAILED EXPORT DATA OF TOUGHENED GLASS    
DETAILED IMPORT DATA OF TEMPERED CLEAR GLASS    
B.I.S. SPECIFICATION    
TOUGHENED GLASS    
CHARACTERISTICS OF TOUGHENED GLASS    
PROPERTIES OF TOUGHENED GLASS    
BENEFITS:    
STRENGTH & SAFETY CONSIDERATIONS    
RESISTANCE TO THERMAL BREAKAGE    
PROPERTIES    
APPLICATIONS OF TOUGHENED GLASS    
ADVANTAGES:    
TOUGHENED WINDOW PANES:    
MANUFACTURING PROCESS OF TOUGHENED GLASS    
GLASS CUTTING    
GLASS POLISHING:    
DRILLING & MILLING    
GLASS WASHING    
TOUGHENING    
PROCESS FLOW DIAGRAM    
PROCESS OF TOUGHENED GLASS IN DETAILS    
GLASS CUTTING    
GLASS POLISHING    
DRILLING AND MILLING    
GLASS WASHING    
TOUGHENING OR TEMPERING    
TOUGHENING PROCESS    
WASHING AND DRYING    
USES AND APPLICATIONS    
GENERAL USES OF TOUGHENED GLASS:-    
AUTOMOBILES    
BUILDINGS AND STRUCTURES    
FOOD SERVICE    
COOKING AND BAKING    
MOBILE DEVICES    
PROPERTIES & CHADRACTERISTICS    
THE COMPOSITION OF GLASS:-    
MECHANICAL PROPERTIES OF TOUGHENED GLASS    
DIMENSIONS FOR TOUGHENED SAFETY GLASS USED WITH ROUND WINDOWS    
ALL DIMENSIONS IN MILLIMETERS    
PROCESS OF MANUFACTURE FOR LAMINATED SAFETY GLASS    
SAFETY LAMINATION:-    
FORMULATION    
FLOW SHEET    
MANUFACTURING PROCESS OF INSULATED GLASS    
GLASS LITES:    
FRAME:    
DESICCANT:    
SEALANT:    
FILLING:    
GAS-FILLING EQUIPMENT    
THE CHAMBER METHOD    
LANCE AND PROBE METHOD    
TECHNICAL IDENTIFICATION OF SODA-LIME FLAT GLASSES    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)    
SUPPLIERS OF PLANT AND MACHINERY    
SURFACE GRINDING MACHINE    
POLISHING MACHINE    
GLASS DRILLING MACHINE    
GLASS CUTTING MACHINES    
LATHE MACHINE    
SUPPLIERS OF RAW MATERIALS    
SHEET GLASS    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET