PRESENT OPERATIONS Presently the Company operates a 210 Tons/day glass-melting furnace with five glass forming lines. We manufacture flint Glass bottles and jars with latest ACL Printing mainly for the liquor, food and pharmaceutical industry. The salient features of this new plant in two floors commissioned in March 1995 with an investment of Rs.41 crores are as follows: Raw Material Abundant quality of superior quality low iron Silica Sand is available from own mines located close to the plant. We have facilities to beneficiate and demagnetise the Silica Sand before charging it to the Silos. Other minerals like Calcite, Dolomite and Feldspar are procured in processed condition and final sieving and demagnetising is done at our premises. Soda ashes, Sodium Nitrate, Sodium Sulphate along with other minor chemicals of internationally acceptable quality are also available locally. Presently, we use 40% cullet out of which 25% is outside cullet, which is washed, crushed, sorted and demagnetised at the plant to a high level of purity in our cullet treatment plant. Batch Plant Using state of the art load cells, batching controllers, weight indicators and PLCs, interfaced with a range of feeders, hoppers, conveyors and a TEKA/MILLER TZ1875 Pan Mixer, the batching process is automated to achieve consistent accuracy in precise proportioning and mixing of raw materials. Inside and outside cullet are stored in separate silos and added to the batch conveyors in the inside cullet return system the crushed plant rejection cullet is charged into the silos automatically. Furnace The 68 Sq.Meter end fired two pass regenerative furnace was designed by KTG (UK). It incorporates microprocessor controlled temperature, level and pressure control as well as automatic fuel/air reversal system. Low Sulphur High Stock oil is used as fuel in the furnace and High-speed diesel is used as fuel in working end. The working end has 3 zones with separate automatic temperature controls. Forehearths Five forehearths all L.P.G. fired of contemporary design condition the glass to the feeders. Two of the larger forehearths - K 36 x 24' and K 30 x 24' have 3 zone auto heating/cooling system with tri level thermocouples at rear, middle and conditioning sections in addition to three other single point thermocuples ensuring a high degree of thermal homogeneity. The other three smaller forehearths KW 26 x 20' x 2 nos. and KU 16 x 14' have 3 zone with radiomatic temperature controls. The LPG/air mixing is through zero governers and inspirators. Glass forming Machines There are five I S Machines giving a high degree of flexibility to produce a large range of bottles and jars to cater to large as well as small orders. Quality Assurance The two larger production lines are provided with single liners, dual inspection stations and lowerators for transporting bottles to the ground floor for packing. The inspection on all five lines is presently manual. AGR dual head ramp pressure tester, Thermal shock testing machine and a well equipped analytical and chemical laboratory doing density, chemical analysis of glass and microscopy are some of the facilities available. Packing Shrink packing machines are attached to all the five lines and depending on customer preferences the bottles/jars are shrink packed or filled in cartons. ACL Printing Facility We have ACL printing facility @ 2,10,000 bottles per day. We have 3CS-150 STRUTZ (USA make) machine which can print 3 colors on shoulder and 3 colors on body, total six colors printing. We can print the Beverage (Round) bottles from 200 ml to 1200 ml. The facility is fully online. The bottle is not handled manually right from IS Machine till packing after printing. Services Mould shop We manufacture 90% of the moulds in our Workshop. The workshop is equipped with a wide range of machines and highly skilled personnel. Electrical 3 x 1600 KVA transformers with matching switchgear receives and distributes power from the State Electricity Board. Full standby generating facility is available consisting of one slow speed 4000 KVA FUJI D.G.Set, two nos. 500 KVA DG Sets and one 320 KVA D.G.Set. PROPOSAL FOR FUTURE Adding one more bottle making machine to utilise the full capacity of the furnace keeping the viability of the unit. We have the basic infrastructure to add one more glass-melting furnace of smaller capacity with 2/3 forming lines to produce green/amber bottles. PERSONNEL The unit is located in a 100% literate state with abundant availability of skilled and educated personnel. We have a well-qualified and skilled team of technical and commercial Officers.