The document provides an overview of the bangle industry in India. It discusses that major production centers are in Moradabad and Firozabad in Uttar Pradesh. The raw materials, tools, and process for bangle production are described. This includes melting raw materials in furnaces, shaping the glass, and cutting it into bangles. Challenges facing the industry like child labor, fuel costs, and lack of technology are also summarized. Suggestions to address issues like occupational health, energy efficiency, and awareness are provided.

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.

8. Tank Furnace

9. Sekai Bhatti

10. Shaping

11. Belan Bhatti

12. Cutting

13. Joining

14. Decoration(Zari)

15. Final 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.

22. Thank You