Toughened Glass, Tempered Glass and Safety Glass Industry: Global Demand for Toughened Glass will continue to Increase – An Investment Opportunity Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue, Plant Economics, Production Schedule, Working Capital Requirement, Plant Layout, Process Flow Sheet, Cost of Project, Projected Balance Sheets, Profitability Ratios, Break Even Analysis

 

Glass making, one of the oldest of industries, has had a fascination for man throughout the ages. The transmutation of common sand and earth into a gem- like, rigid, transparent material has all the romance of alchemy. Today, by far the greater volume of glass is made by fully automatic means, and a visit to a modern bottle factory, the glass technologist is the alchemist behind the scenes who must daily exercise his art, assisted by science, to ensure that the machines are capable of functioning properly.

Glass truly has become symbolic of communication and openness in architecture today. Combining technological advantages with glass, designers have plunged forward to experiment with its various facets.

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 (aka: annealed glass) creates. The granular chunks are less likely to cause injury. The product is employed in numerous applications including shower doors, passenger vehicle windows, refrigerator trays, architectural doors and tables, a component in the manufacturing of bullet proof products, mobile screen protectors, cookware and diving masks on account of superior properties including high strength and safety features.

Toughened Glass has to pass the following important tests:

·         Transfer strength test on sheets on simply supplied (Modules of rupture and electricity)

·         Impact test: By following weight on sheets supported on two wooden battens

·         Impact by falling weight on sheet evenly bedded (on putty)

·         Impact by falling weight on edge of sheet

·         Repeated twisting tests

·         Sand blast abrasion

·         Thermal tests

 

Because of the strength and other specific physical properties mentioned above, itfinds applications in the following fields:

·         Automobile: Cars, trucks,

·         dustry buses, tempos etc.

·         Railways: Coaches

·         Defence: Fleets, vehicles factory

·         Commercial: Hotels, shops, complex

·         Air ports: Doors

In recent years, several changes in legislation and standards have made the use of safety glass in critical locations compulsory by law. Apart from the obvious uses of toughened glass in windows, doors and conservatories, etc., it is widely utilised in squash and handball courts, canopies and roofs, cabinets, table tops, balustrades for stairways and balconies and entrance door assemblies.

Properties

Toughened glass is physically and thermally stronger than regular glass. The greater contraction of the inner layer during manufacturing induces compressive stresses in the surface of the glass balanced by tensile stresses in the body of the glass. For glass to be considered toughened, this compressive stress on the surface of the glass should be a minimum of 69 megapascals (10,000 psi). For it to be considered safety glass, the surface compressive stress should exceed 100 megapascals (15,000 psi). The greater the surface stress, the smaller the glass particles will be when broken.

 

Market Potential

The glass industry comprises five main sectors covering different glass products, applications and markets. These sectors are very different, whether in terms of manufacturing process, products, markets, the economics of the sectors or manufacturers, but they all transform raw materials into glass by a process of melting. More than 90 per cent of glass industry products are sold to other industries. Glass manufacturing is thus significantly dependent on the building construction sector, car manufacturing and the food and beverage industry. However, there are also smaller volume sectors that produce high-value technical or consumer products.

With increased transportation facilities the demand of the product is increasing at a steady pace especially in the automobile industry, railways, ships building both for production and replacement. Local market and advertisement has become very essential for the success of any business activity. As such it is found to have scope for starting new small scale units for the manufacture of Toughened glass to meet the growing demand.

The market for toughened glass is currently growing at 15% per annum. The construction boom and increasing safety standards will see the demand for toughened glass continue to increase. Within the industry, the double glazing and toughened glass markets are relatively low growth markets, with stable shares and profit margins. The potential growth markets are seen as coming in diversified areas such as kiosks, shower units and refrigeration case manufacturing.

Global Toughened or tempered glass market is expected to reach USD 54.31 billion by 2022.

 

PRESENT MANUFACTURERS

Asahi India Glass Ltd.

Atul Glass Inds. Ltd.

Auroplast India Ltd.

Gold Plus Glasses India Ltd.

Hindusthan Safety Glass Works Pvt. Ltd.

Saint-Gobain Sekurit India Ltd.

 

Table of Contents

 

1.       Project Location

1.1.    District Profile & Geotechnical Site Characterization

1.1.1.General

1.1.2.Topography

1.1.3.Map

1.1.4.Rainfall & Climate

1.1.5.Language & Culture

1.1.6.Transportation

1.1.7.Economy & Industry

2.       Introduction

3.       Toughening

3.1.    Chemical Nature of Glass Forming Materials

4.       Characteristics of Tempered Glass

5.       Advantages and Disadvantages of Toughened Glass

5.1.    Advantages

5.2.    Disadvantages

6.       Properties

6.1.    Degree of Toughness

6.2.    Dealing with Distortion

6.3.    Physical Properties

7.       Uses and Applications

8.       Market Survey

8.1.    Glass Products

8.2.    Flat Glass

8.3.    Leading Brands

8.4.    Market Structure

9.       Financials & Comparison of Major Indian Players/Companies

9.1.    About Financial Statements of CMIE Database

9.2.    Profits & Appropriations

9.3.    Total Liabilities

9.4.    Total Assets

9.5.    Net Cash Flow from Operating Activities

9.6.    Section – I

9.6.1.Name of Company with Contact Details

9.6.2.Name of Director(S)

9.6.3.Plant Capacity

9.6.4.Location of Plant

9.6.5.Name of Raw Material(S) Consumed with Quantity & Cost

9.7.    Section – II

9.7.1.Assets

9.7.2.Cash Flow

9.7.3.Cost as % Ge of Sales

9.7.4.Forex Transaction

9.7.5.Growth in Assets & Liabilities

9.7.6.Growth in Income & Expenditure

9.7.7.Income & Expenditure

9.7.8.Liabilities

9.7.9.Liquidity Ratios

9.7.10.    Profitability Ratio

9.7.11.    Profits

9.7.12.    Return Ratios

9.7.13.    Structure of Assets & Liabilities (%)

9.7.14.    Working Capital & Turnover Ratios

10.   Export & Import Statistics Data of India

10.1.Export Statistics Data Toughened Glass

10.2.Import Statistics Data Toughened Glass

11.   Present Manufacturers

12.   Raw Material

13.   Manufacturing Process

14.   Process Flow Diagram

15.   Features of Bevelling Machine

16.   Technology

17.   Suppliers or Raw Material

18.   Suppliers of Plant & Machinery

19.   Plant Layout

20.   Machinery, Raw Material & Product Photographs

20.1.Machinery Photographs

20.2.Product Photographs

20.3.Raw Material Photographs

21.   Quotation of Plant, Machinery and Equipments from Supplier

 

PROJECT FINANCIALS

·         Project at a Glance

Annexure

·         Assumptions for Profitability workings ….…………………………………………....................... 1

·         Plant Economics…………………………………………………………………………….................... 2

·         Production Schedule……………………………………………………………………….................... 3

·         Land & Building…………………………………………………………………………….................... 4

§  Factory Land & Building

§  Site Development Expenses

·         Plant & Machinery………………………………………………………………………….................... 5

§  Indigenous Machineries

§  Other Machineries (Miscellaneous, Laboratory etc.)

·         Other Fixed Assets………………………………………………………………………….................... 6

§  Furniture & Fixtures

§  Pre-operative and Preliminary Expenses

§  Technical Knowhow

§  Provision of Contingencies

·         Working Capital Requirement Per Month………………………………………………................. 7

§  Raw Material

§  Packing Material

§  Lab & ETP Chemical Cost

§  Consumable Store

·         Overheads Required Per Month and Per Annum ……………………………………................. .8

§  Utilities & Overheads (Power, Water and Fuel Expenses etc.)

§  Royalty and Other Charges

§  Selling and Distribution Expenses

·         Salary and Wages ……………………………………………………………………………................. 9

·         Turnover Per Annum ………………………………………………………………………................ 10

·         Share Capital…………………………………………………………………………………................ 11

§  Equity Capital

§  Preference Share Capital

 

•        Annexure 1            ::        Cost of Project and Means of Finance

•        Annexure 2            ::        Profitability and Net Cash Accruals

§  Revenue/Income/Realisation

§  Expenses/Cost of Products/Services/Items

§  Gross Profit

§  Financial Charges    

§  Total Cost of Sales

§  Net Profit After Taxes

§  Net Cash Accruals

 

•        Annexure 3            ::        Assessment of Working Capital requirements

§  Current Assets

§  Gross Working Capital

§  Current Liabilities

§  Net Working Capital

§  Working Note for Calculation of Work-in-process

 

•        Annexure 4            ::        Sources and Disposition of Funds

•        Annexure 5            ::        Projected Balance Sheets

§  ROI (Average of Fixed Assets)

§  RONW (Average of Share Capital)

§  ROI (Average of Total Assets)

 

•        Annexure 6            ::        Profitability ratios

§  D.S.C.R

§  Earnings Per Share (EPS)

§  Debt Equity Ratio

 

•        Annexure 7            ::        Break-Even Analysis

§  Variable Cost & Expenses

§  Semi-Variable/Semi-Fixed Expenses

§  Profit Volume Ratio (PVR)

§  Fixed Expenses / Cost 

§  B.E.P

 

•        Annexure 8 to 11   ::        Sensitivity Analysis-Price/Volume

§  Resultant N.P.B.T

§  Resultant D.S.C.R

§  Resultant PV Ratio

§  Resultant DER

§  Resultant ROI

§  Resultant BEP

 

•        Annexure 12          ::        Shareholding Pattern and Stake Status

§  Equity Capital

§  Preference Share Capital

 

•        Annexure 13          ::        Quantitative Details-Output/Sales/Stocks

§  Determined Capacity P.A of Products/Services

§  Achievable Efficiency/Yield % of Products/Services/Items 

§  Net Usable Load/Capacity of Products/Services/Items   

§  Expected Sales/ Revenue/ Income of Products/ Services/ Items   

 

•        Annexure 14          ::        Product wise domestic Sales Realisation

•        Annexure 15          ::        Total Raw Material Cost

•        Annexure 16          ::        Raw Material Cost per unit

•        Annexure 17          ::        Total Lab & ETP Chemical Cost

•        Annexure 18          ::        Consumables, Store etc.

•        Annexure 19          ::        Packing Material Cost

•        Annexure 20          ::        Packing Material Cost Per Unit

•        Annexure 21          ::        Employees Expenses

•        Annexure 22          ::        Fuel Expenses

•        Annexure 23          ::        Power/Electricity Expenses

•        Annexure 24          ::        Royalty & Other Charges

•        Annexure 25          ::        Repairs & Maintenance Expenses

•        Annexure 26          ::        Other Manufacturing Expenses

•        Annexure 27          ::        Administration Expenses

•        Annexure 28          ::        Selling Expenses

•        Annexure 29          ::        Depreciation Charges – as per Books (Total)

•        Annexure 30          ::        Depreciation Charges – as per Books (P & M)

•        Annexure 31          ::        Depreciation Charges - as per IT Act WDV (Total)

•        Annexure 32          ::        Depreciation Charges - as per IT Act WDV (P & M)

•        Annexure 33          ::        Interest and Repayment - Term Loans

•        Annexure 34          ::        Tax on Profits

•        Annexure 35          ::        Projected Pay-Back Period And IRR

 

 

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