glass industry(visit to gunj glass pvt.ltd)

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Gunj Glass

Adnan Aslam B.sc Mechanical Engineering HITEC university Taxila, Islamabad Pakistan

“Composer”

Geographic Location

Gunj Glass Works Lim-ited

Address:  N-5, Hassan Abdal

Head Office:A/26 S.I.T.E Area,

Manghopir Road Karachi,Sindh Pakistan.

• Gunj Glass was built in 1987 and its approximate production rate is 120 tons per day.

• Ali glass was built in 1995 and its approximate production rate is 80 tons per day.

• Production capacity of whole plants is approximately 200 tons per day.

“Gunj Glass Works”

Sheet Glass are manufactured with a thickness from 2mm to 12mm.

There are to separate settlements; one for glassware and the other for glass sheets.

RAW Materials

The main raw materials used for glass manufacturing are:

Silica Sand ( both washed and unwashed) Limestone Dolomite Soda Ash Cobalt and Selenium

Composition of Materials

Reason for Adding these ma-terials

Silica Sand

A fine white sand and it is needed because it is very pure and does not contain other un-wanted chemicals.

RAW Materials

Limestone is added to give durability to the glass.

Dolomite is added to give strength to the glass

Soda ash is added to decrease the melting point of Silica sand.

Cobalt and Selenium are used only for table wear products

Cobalt gives blue colour to glass

Selenium gives pink colour to the glass.

If both Cobalt and Selenium are used together they will give green colour to the glass.

RAW Materials

Block Diagram

Manufacturing

FOLLOWING ARE THE STEPS FOR THE MANUFACTURING OF GLASS:

MELTING

SHAPING AND FORMING

ANNEALING

FINISHING

MELTING:

Raw materials are now subjected to melting in furnace.

TANK FURNACE

70 ton capacity Continuous processes. temperatures ranges from 1400 to 1600*c Acidic or basic Refractory Bricks

SHAPING OR FORMING

With the combination of “mold” and “ plunger” different shapes of glasses can be made.

Approximately “1” mold give 20-25 lakhs pieces and import from China due to lack of machinery in Pakistan.

Tempered glass:

This is very strong and used in doors and windows.

For this “Edging machine” and “Bending machine” used. The temperature can be maintained about 650*c.

Cooling take place by ambient Air.

Strength Test

By dropping 1kg of ball at 1m height, glass

can be withstand without any damage.

Glass passing this test will be able to bear the 10,000 Psi pressure.

Insulated Glass:

Two layers of glass is used for making insu-lated glass:

Simple glassReflective glass

WORLD TRADE CENTRE in Bahria town is made from insulated glass.

ANNEALING:

To reduce internal stresses, annealing takes place.

Walls are comparatively thick and cooling will not be even.

The inner and outer skins of a glass become rigid.

The still contracting inner portion build up internal stresses.

Uneven cooling develop substantial stresses in the glass.

Improperly annealed glass are fragile and high breakage.

PRODUCTION RATE

Production rate depends on product requirement:

Capacity: Maximum 70 ton/day

Work rate 40 ton

90-98000 pieces per day

ISO Standards

It is necessary for any industry that must follow some quality and environment rule of International organization for standardization to sale his product in international market.

Quality Standards

ISO 9001Environmental Standards

ISO 14001

Power Plant/power genera-tion

Main Source: WAPDA

Fuels: Natural Gas E-Gas Furnace Oil

Pet coke plant in going to be installed. Their initial cost is high but later on its cheaper.

Global Labour Rights

No safety for workers

Employees Old-Age Benefits Institution (EOBI)

No facility of Social Security