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Bangle industry in india (NBMS Model)
1. Indian Institute of Technology (IIT)-Delhi
RDL-702
Bangle Industry in India
Shubham Srivastava Shubham Saini
(2017JIT2122) (2017JIT2782)
2. Contents
Overview of the Industry
Tools & Raw material
Process
NBMS Model for Bangle Industry
Energy Efficiency
Challenges before the Industry
Suggestions
3. Overview of the Industry
• Known in India since ages i.e. Statue of a Dancing Girl wearing Bangles found at
Mohenjodaro.
• Major Centers of Production:
Moradabad (UP) – Largest producer of bangles in the World.
Firozabad (UP-Glass city) – Largest producer of glass bangles in the World.
(accounts for 70% of the total glass production )
Hyderabad – Largest Market for Bangles in India.
a) Daily Revenue = 30 lac
b) People Employed = 4000, out of which 60% are women.
4. Overview of the Industry
• Bangle Making Process
• Bangles can be made from:
1. Metal
2. Plastic
3. Wood
4. Lac
5. Glass
5. Tools & Raw material
• Raw Material-Soda ash and silica are the main raw materials used in
the production of glass.
• Tank Furnace: The raw materials are melted in the furnace at a
temperature of about 1300 to 1400 C to obtain molten glass.
• Pakai Bhatti: The bangles are baked in a furnace called pakai bhatti
which smoothens the sharp edges and makes the bangles bright and
attractive.
• Belan/Spindle: Long steel rod that is rotated to draw glass melt into
spirals, which are then cut to make raw bangles.
• Zari: A glittering strip used to make patterns on the bangle.
6. Process
• First, a worker (known as the gulliwalla) uses a long iron pole to scoop out
a glob of molten glass from the pot furnace at a temperature of around
1300 °C.
• He gives the glob to a worker who gives it an appropriate shape. If
necessary, he coats the glass with a small quantity of colored block glass
that is melted separately in a small refractory container called tali.
• The shaped glob is then taken to the Sekai Bhatti which gives it a roughly
cylindrical shape by rotating the rod.
• The still-soft cylindrical mass of glass, now cooled down to a temperature
of around 500 °C, is then taken to a furnace, the Belan Bhatti where it is
rotated, covered with thin filament of glass and cut at periodic intervals.
7. Process
• The spiral lengths of glass that get cut off at lengths are collected.
• The cut bangles are tied with strings into bunches. Each bunch
contains approximately 320 bangles, and is called a tora.
• The bangle bunches are then sent to household units for further
processing into ‘raw’ bangles
• Finally, the raw bangles are annealed in a furnace known as the Pakai
Bhatti to yield the finished product.
16. NBMS Model for Bangle Industry
S-Level
• Raw material collection-Silica Sand, Soda ash, Dyes.
• Sieved, weighed and mixed.
M-Level
• Glass Melting in open pot furnaces (in Batch of 10-12)
• Shaping the glass ball using Mason’s patter
• Coloration
• Reheat
• Sekai and Belan Bhatti (rotating shaft arrangement).
17. NBMS Model for Bangle Industry
B-Level
• Cutting-Diamond tip cutter.
• Pattern printing and finishing
• Bundling- in batches of 320, called TODA.
N-Level
• Marketing & Advertising
• Shipping & Exporting
18. Energy Efficiency
• Major Energy Input = Natural Gas.
• Per Unit Consumption = 3500m3/day (continuous run of 8-9hrs)
• 1 Cluster = 200-250 Units.
19. Energy Efficiency
• Types of Losses:
1. Thermal loss
• Furnaces are not well designed and insulation material used is of poor quality.
2. Combustion loss.
• Poor Quality burners
3. Heat Recovery loss.
4. Absence of monitoring & control system along with manual control of regenerator
has further deteriorated the efficiency of tank furnaces of different capacities in the
cluster.
=> The envisaged energy saving is 30-35% equivalent to 48 million Sm3 per year at
cluster level.
20. Challenges before the Industry
• Largest employer of child labor in India.
• 30-35% input cost is fuel, severely affected by price variability.
• Competition from China.
• Technology related to glass melting, forming and shaping has remained
primitive.
• Only a handful of Indian companies manufacture soda ash- a key input for
the industry.
• The labourers work in hazardous conditions amid toxic fumes and
unbearable heat. Many of them develop serious ailments.
• lack of the availability of most modern technology, promotion and a lack of
product innovation/ variation.
21. Suggestions
• Some occupational and health hazard measures should be
implemented in the factory to avoid any kind of accident.
• Workers in the factory should wear face masks, gloves etc. for their
own safety and health benefits.
• If possible, more energy efficient techniques should be tried to bring
in practice as it will reduce the energy consumption of the industry
and will maintain better ambient and outside air temperature.
• Awareness about the basics of energy saving, safety and health
concerns should be made among the local masses.
