Industrial Training

Report

At
Piramal Glass Pvt. Ltd.
Kosamba Plant

By:-
Sukriti Bhardwaj
&
Vijay Krishan Gupta
Ceramic Engineering
IT- BHU

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 CONTENTS
1. Acknowledgments………………………………………………………………...3
2. Introduction……………………………………………………………………….4
3. Kosamba Plant………………………………………………….…………………6
4. Departments………………….…………………………………………………...7
5. Glass Manufacturing Process……………………………………………………..8
6. Overview of Food and Pharma Department...……………………………………11
7. Overview of Cosmetics and Perfumes Department……………………………....13
8. Conversion of 65 TPD furnace to 95 TPD furnace……………………………….15
9. Project Report……………………………………………………………………..17
10. Conclusions and future work……………………………………………………. 21
11. Experiences at Piramal Glass……………………………………………………...22

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 Acknowledgements
I am greatly thankful to Mr. K. Ramachandran and Mr. Jignesh Vaidya for their
tremendous support and co-operation during the project.

I am really thankful to my mentors Mr. M.V. Rao and Mr. M.S. Reddy for giving us
an opportunity to gain knowledge in the field of glass manufacturing.

I am also thankful to Mr. Bipin (Batch House), Mr. Devender Kumar, Mr.Ravi and
Mr.Sameer(Chemical Lab). Their help made the project a good learning
experience into the realms of glass industry.

I am also thankful to all the employees at Piramal Glass Ltd., Kosamba for their co-
operation throughout the project.

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 Introduction
Piramal Glass:

Piramal Glass Ltd. is a leading manufacturer of glass packaging for

pharmaceutical, cosmetic and perfumery products. A dynamic venture of Piramal
Enterprise, Piramal Glass Pvt. Ltd. was established in the year 1976, with the
name Gujarat Glass Ltd. and was then acquired by Piramal Group in 1984.

The esteemed organization has all four certifications:

 ISO 9001 (Quality)

 ISO 14001 (Safety)

 OHSAS 18001 (Environmental care)

 SA 8000 (Social Accountability)

Since the time Piramal Glass was acquired, its products were strategically for the
healthcare industry, has focused on being the leading provider of “flaconnage”
with a compounded annual sales growth of over 35%.

Piramal Glass Ltd. is the only company in India and one of the few in the world,
which manufacture and market the entire pharmacy range of glass bottles and
vials (Glass Type 1, 2 & 3). Company stands in the world market without any
competitor in the field of nail polish bottle manufacturing.

Piramal Glass plants at various locations:

Furnaces Production (TPD) Production Lines Location

6 at Kosamba 340 23 Gujarat
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2 at Jambusar 335 12 Gujarat
1 at Sri Lanka 205 5 Sri Lanka
2 at USA 230 9 USA

The group has diversified business ventures in:

 Textiles

 Auto Ancillaries

 Cutting tools

 Health care

 Hard ferrites

 Glass containers

 Information Technology

 Hospital

 Malls and Supermarket

Vision of the Plant:

To be amongst the top three flaconnage (glass bottle) manufacturers in the world.

Organizational Values:

 Continually enhancing value for our customers with quality products and
services to meet their changing needs.

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  Empowering our employees, encouraging innovation and entrepreneurship
in an environment, which makes work fun.
 Steadily building wealth for shareholders.
 Contributing to the well being of society and the environment.

Kosamba Plant
Kosamba Plant is located between Surat and Bharuch in main Mumbai Baroda
line. The plant consists of six furnaces with 23 production lines. All three types of
glass (Type 1, 2 & 3) Color Amber or Flint (White) are produced. Three furnaces
with production of 40, 45 and 55 tons per day (TPD) are serving mainly Pharmacy,
Chemical and Food and the other three furnaces with production 65, 35 and 100
TPD are serving for Cosmetic and Perfumes. One production line (S18) is with
color Fore hearth, so as to give any color glass for the customer requirements.

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 Departments:
 Glass

 Production

 I.S. Maintenance

 Electrical and Instrumentation

 QC, QA

 Packaging and Dispatch

 Stores

 Production planning and production engineering

 Engineering services

 Chemical laboratory

 Mould manufacturing

 Systems (I.T.)

 H.R.

 Safety

 Purchase

 Accounts

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 Glass Manufacturing Process:
The glass container manufacturing process consists of five basic operations,
namely:

1. Batch Preparation
2. Glass Melting and Conditioning
3. Glass Container Forming
4. Annealing of glass containers
5. Inspection, packing, storage and dispatch

The basic raw materials used for manufacture of glass container are silica
sand, quartz, dolomite, calcite, soda ash, fine chemicals and cullet (broken
pieces of recycled glass). The utilities used in the manufacture of the
container are fuel (oil/natural gas), electricity (for various electrical
consumers such as motors, lighting, etc.) and compressed air for the
forming operation of the glass containers.

The entire manufacturing process is essentially non-polluting and the

biggest advantage of glass as a packaging material is that it can be recycled
thus lending itself to be the most “environment friendly” packaging
material available today.

1. Batch Preparation: In batch preparation, the raw materials, viz. silica

sand, quartz, soda ash, calcite, dolomite, fine chemicals etc. are weighed
and mixed together in pre-determined proportion to form a composite
mixture. This mixture is then further mixed with a pre-determined
amount of cullet. The resultant mixture is called a batch, which is then
fed to the glass melting furnace. The entire batch preparation is carried
out in a Batch House.

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2. Glass Melting and Conditioning: The raw material mixture, referred
to as a “batch” is charged to the “glass melting furnace” wherein it is
melted into a homogenous solution of molten glass at temperatures
ranging from 1550˚C to 1580˚C. The molten glass is then drawn into a
distributor where the temperature is maintained at 1300˚C from where
the glass is fed to the glass-forming machine through a refractory
channel termed as fore hearth. The distributor consists of as many fore
hearths as number of glass forming machines. Each glass forming
machine and equipments subsequent to it forms a separate production
line. The glass is fed to the glass forming machine by means of a feeder
mechanism located at the end of the fore hearth. The fore hearth is also
heated to maintain glass at a constant temperature ranging from 1090˚C
to 1200˚C. In the fore hearth, a pre-determined quantity of molten glass,
depending upon the weight and size of the container identified to be
produced, called a gob, is separated from the fore hearth at regular
intervals depending upon the production speed, and fed to the glass
forming machine.

3. Glass Container Forming: In the glass forming machine, the gob is

fed to mould and blown to the final shape of the bottle and the bottle so
formed is transferred to the annealing lehrs by means of conveyors and
stackers. The glass forming machine, consists of many individual
sections (typically six eight or ten) with each section having a separate
mould and forming a glass container. These machines in glass
production technology are known as “I.S. machine”. Once the machine
parameters are set according to the size of the container to be
produced, the entire forming operation is automatic.

4. Annealing of Glass Container: During the forming operation, the

formed glass container develops stresses and in order to relieve these
stresses and thereby increasing the glass container strength, the formed

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 bottles are thermally processed in an “Annealing Lehr”. In the annealing
lehr, the bottles are heated to a temperature of approximately 540˚C to
580˚C and slowly allowed to cool in a controlled manner in order to
relieve the stresses.

5. Inspection and Packing: At the end of the annealing lehrs, the

containers are inspected by the quality control department to detect
cracks and other defects developed either from glass or at forming. The
rejected bottles are formed into cullet and recycled back to the batch
house. The accepted bottles are then packed into cartons and stored in
a finished goods ware-house for onward dispatch to the customers
Quality Assurance Department draws samples at random at various
stages and certifies the quality and quantity of product. This process is
prevalent for manufacture of glass bottles throughout the world. The
manufacturing process in Gujarat Glass is on the above lines.

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 Overview of Food and
Pharmaceutical department:
Food and Pharmaceutical department handles the production of amber and flint
glass bottles. There are three production lines in this department.

a) 40 TPD
b) 45 TPD
c) 55 TPD

Three types of glass bottles are produced in these production lines. Type 1 glass
(borosilicate glass) is produced in 45 TPD line. Type 2 and Type 3 (soda lime glass)
is produced in 40 TPD and 55 TPD production lines. Amber glass bottles are
produced in 45 TPD line and flint glass bottles are produced in all the three
production lines.

Raw materials used are as follows:

1) Quartz
2) Borax
3) Feldspar
4) Alumina Hydrate
5) Soda Ash
6) Dolomite
7) Soda Nitrate
8) Barium Carbonate
9) SSF (Sodium Silica-Fluoride)

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12
 Overview of Cosmetics and
Perfumes (C & P) department
Batch House:
There is a common batch house for all 3 furnaces of C & P department viz. 35 TPD,
65 TPD and 100 TPD. Only flint glass bottles are being produced. The raw
materials used are as under:

 Snow White (SW)

 Semi Snow White (SSW)
 Dolomite
 Limestone
 Soda Ash
 Fine chemicals

Processes being employed in batch house:

In batch preparation, the raw materials, viz. silica sand, quartz, soda ash, calcite,
dolomite, fine chemicals etc are weighed and mixed together in pre- determined
proportion to form a composite mixture. This mixture is then further mixed with a
pre- determined amount of cullet (broken pieces of recycled glass). The resultant
mixture is called a batch, which is then fed to the glass melting furnace. The entire
batch preparation is carried out in a batch house.

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Flow Chart representing the
processes in Batch House:

Cullet Sand (SW and SSW) Fine Chemicals

Feeding Hopper Hopper Weighing

Crusher Vibrating Screen Pre- mixer

Magnetic Separator Conveyor Belt Silos

Screening Silos Weighing Hopper

Cullet Silos Weighing Hopper

Weighing hopper

Mixer

Dog Silos

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Conversion of 65 TPD furnace to 95 TPD furnace :
Introduction:
Furnace is a refractory structure which can withstand very high temperature
(around 1500o C). 95 TPD furnace is a regenerative type furnace. Regenerator is
refractory structure which recovers heat and hence required energy input is less
for glass melting.

Regenerator:
The blower blows cold air into the furnace. After melting, hot flue gas is absorbed
into the second column of checker bricks and the cold air is released into the
atmosphere through the chimney. This process is timed for a period of about 20
to 30 minutes. In the first half, the valve direction is changed and the cold blower
air is passed through the second column of checker bricks. But this time it absorbs
heat from checker bricks. After glass melting, the hot air is absorbed into the first
column of checker bricks and the cold air is released into the atmosphere. In the
second half, the valve direction is changed and the cold blower air is passed
through the first column of checker bricks. It absorbs heat from checker bricks.
After glass melting, the hot air is absorbed into the second column of checker
bricks and the cold air is released into the atmosphere. This process is repeated
after every 20 to 30 minutes.

Furnace:
The fuel is Natural gas and oil. But oil is supplied as fuel only in the case of
emergency. The atomiser converts oil into atomic form. The pressurised flames
produced due to natural gas is mixed with hot air, is used for melting of glass. The
batch is passed into the furnace using batch feeder. The molten glass is almost
left stationary till the wear wall. Molten glass circulates for better mixing. The
impurities present in the glass settle down as they are heavier than the pure
molten glass. It starts flowing into the distributor through the duct. The

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distributor distributes molten glass into five fore hearths. Every fore hearths then
distributes the molten gob into six moulds of IS machine .

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 PROJECT REPORT
SUBJECT: To determine the iron content in glass during every step of glass
manufacturing process.

ABSTRACT:
The objective of our project is to determine the iron content in glass after every
manufacturing process. Iron in glass, if present in excess of the permissible levels
can significantly affect its strength and durability (in case of flint glass). So, the
basic aim of the batch house manufacturing processes is to minimize the iron
content as far as possible. The most crucial part of the iron content inspection is
during unloading. It’s the first process from where the sample is taken for testing.
So, if iron content is well within the allowed value in its primary stages, the stress
for minimizing iron can be reduced on the remaining processes and can be carried
out smoothly. The processes after unloading from where the sample was being
tested are: before magnetic separator, after magnetic separator, before mixing,
from cullet, from dog silos and in final glass bottle. The addition of cullet increases
the iron content of the batch mix. Hence the mixing should be proportioned
correctly to get the final product as per specifications.

Procedure:
 Samples of SW and SSW were taken from different locations from the truck.

 Sample was then crushed to fine granules using ball mill. Milling was done
for approximately 20 min.

 Around 12 grams of the crushed sample was taken and was mixed with
binder wax.

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  10 grams of the mixture is then taken in a pallet mould and pressed in a
pressing machine having pressure of 20 tons.

 Pallet is then put in XRD machine. This machine automatically determines

the composition of the sample. Time taken is around 3 minutes for 1 pallet.

Observations:
Iron content in SEMI SNOW WHITE QUARTZ:

Piramal Glass Specifications: 0.025% of Fe2O3 during Unloading

Process SSW (% Fe2O3)

1. Unloading

A) Hindustan Minerals 0.024

B) Quality Quartz 0.0217

C) Badri Minerals 0.023

D) Swaraj Minerals 0.023

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 E) Foremost Minerals 0.018

2. Before Magnetic Separator 0.028

3. After Magnetic Separator 0.015

4. After Silos/ Before Mixing 0.024

Iron content in SNOW WHITE QUARTZ:

Piramal Glass Specification: 0.01% of Fe2O3 during Unloading

Process SW (% Fe2O3)

1. Unloading

A) Harshita Mines & Minerals 0.007

B) Palash Minerals 0.006

C) Foremost Minerals 0.007

2. Before Magnetic Separator 0.0249

3. After Magnetic Separator 0.0117

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 4. After Silos/ Before Mixing 0.0157

Iron content in Processes after mixing:

Process 100 TPD (% Fe2O3) 35 TPD (% Fe2O3)

After Mixing/Batch 0.034 0.0347

Cullet from conveyor belt Sample I: 0.147 -

Sample II: 0.0274 -

From dog silos 0.0314 -

Final Product/Glass 0.031 0.028

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PRECAUTIONARY MEASURES:
1. Sampling of materials should be done properly specially during unloading.
Samples should be taken from 8- 10 different locations of the truck in order
to get the average and more precise value of iron content.
2. If the sample is in wet form then it should be first dried before examining it
for iron content.
3. Samples should be labeled properly to avoid confusion.
4. Safety masks, ear plugs and helmet should be used wherever necessary.
5. Fine cullet should be avoided as far as possible.
6. Proper rubber lining must be used.
7. Direct contact with the iron metal should be avoided.
8. Cullet should be handled properly.

Results and Future Prospects:

Iron content in the final product finished glass is mainly due to cullet. However,
each process is responsible for increasing the iron content. At the time of
unloading care is taken to minimize the level of iron content as far as possible. If
the iron content increases beyond Piramal Glass specifications then the truck is
rejected at the time of unloading. Also a magnetic separator is present in the
batch house to minimize iron content. Magnetic separator should be changed
from time to time to increase its efficiency. Also strong magnets are employed at
various places in the batch house to extract iron content from the raw materials.

To reduce the iron content in the finished glass we may produce glass for 15days
only from the raw materials excluding the cullet since cullet is the main reason for
increasing the iron content in glass. But for making this idea feasible firstly we
have to calculate the cost required for the raw materials for 15days and check if it
is affordable. Then we may get finished product containing comparably lesser
content of iron.

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Experience at Piramal
Glass
Having worked in core ceramic industries during our internship in 2nd year,
this time we wanted to explore the field of glass and couldn’t get an
opportunity better than PGL. The glass related experiments which we
performed in our college laboratories were on a very small scale and hence
it was a great experience knowing about the commercial production.

The common feeling that all employees of PGL share, irrespective of the
nature of their work is that they work with utmost level of responsibility and
are always ready to extend their help and support. They abide by all safety
rules, which has helped the industry to attain its aim of zero accidents.

In short, it was a new pragmatic exposure and great learning experience

working with Piramal Glasses Ltd.

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