PAPER PRESENTATION BY

ABHISHEK KUMAR
Sr. Officer (Mktg)
GAS AUTHORITY OF INDIA LTD.
AGRA

April 2003

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 CHAPTER-1

About Glass Industries @ F i r o z a b a d

Firozabad City, where people breathe not air but glass, where every second vehicle on the road
is found fully loaded with glittering bangles of vivid colours. In this city, if you will stay for two
days, you will find it very difficult to imagine that, if it had not been for glass, then what this city
would have done.

Firozabad is located in north central India, in western Uttar Pradesh state,

40 kms.away from Agra and around 200 Kms. away from Delhi, at the northern edge of the
Deccan Plateau. Longitude is 78 degree of east and latitude is 27 degree of north.The height
above sea level is 164.467 meters. The District is well connected by rail and bus routes to major
cities.The nearest Airport is Agra .The boundaries of district touch Etah district in north and
Mainpuri and Etawah districts in the east. The Yamuna river makes its southern boundary.

The area of district is about 0.8% of total area of U.P. and population is 1.1% of total population of
U.P. Approximately, 73.6% population is living in rural area. More than half of the workforce is
engaged in manufacturing activities.The city is also an important market center. It has severe
winter and summer seasons. Mostly district is plane and its slope is from north west to south.

Historic Background

Firozabad was known as Chandwar nagar in ancient times. The name Firozabad was given in the
regime of Akbar by Firoz Shah Mansab Dar in 1566. It is said that Raja Todarmal was passing
through this town, on a pilgrimage to Gaya. He was looted by robbers. At his request, Akbar the
great sent his Mansab Dar Firoz Shah here. He landed near or about Datauji, Rasoolpur,
Mohammadpur Gajmalpur, Sukhmalpur Nizamabad, Prempur Raipura. The tomb of Firoz Shah
and ruins of Katra Pathan are the evidences of this fact. Mr. Peter, who was the businessman,
related to East India Company visited Firozabad on 9th of August 1632 and found the town in
good condition. It is written in the gazetteer of Agra and Mathura that in 1596 Firozabad was
upgraded to a Pargana. Firozabad was bestowed to Nawab Sadulla as jagir, in the regime of
Shahjahan. Jahangir ruled here since 1605 to 1627. Etawah, Budaun, Mainpuri, Firozabad were
under first class mansabdar of emperor Farrukhsiar. Bajirao peshwa looted Firozabad and
Etmadpur in 1737 in the regime of Mohammad Shah. Jats of Mahawan attacked Faujdar Hakim
Kajim at Firozabad and killed him on 9 May 1739. Jats ruled Firozabad for 30 years. Gajuddin,
Hidayat Vaksh son of Alamgir second his nephew and Mirza baba the son in law, came to
Firozabad. Mirza Nabab Khan stayed here till 1782. In the end of 18th century Firozabad was
ruled by Himmat Bahadur Gusain with cooperation of Marathas. The French, Army chief of
Marathas D. Wayan, established an ordnance factory in November 1794. Mr. Thomas Traving
also mentioned this fact in his book "Travels in India ". Marathas appointed his subedar
Lakwadads here who made a fort near old tehsil, known at present as garie. General Lek and
General Vellajally attacked Firozabad in 1802. In the begining of British regime Firozabad was in
Etawah district but after sometime it was attached to Aligarh district. When Sadabad was created
a new district in 1832, Firozabad was attached to it. Later on, in 1833 Firozabad was attached to
Agra. In 1847, the business of lac was flourishing at Firozabad. In 1857, Chauhans of Mainpuri,
Jamidar of Chandwar with local Mallahs took active parts in freedom struggle. Famous Urdu poet
Munir Shikohabadi too was sentenced to Kala pani by East India company government. People of
this city took part in "Khilafat Movement","Quit India Movement" and "Namak Satyagrah" and
went to the jail during these national movements . In 1929, Father of Nation Mahatama Gandhi, in

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1935 Semant Gandhi, in 1937 Pandit Jawahar Lal Nehru and in 1940 Netaji Subash Chand Bose
visited Firozabad. Firozabad district was finally established on 5th of February 1989.

Evolution of Firozabad Glass Industry

During ancient period, invaders brought many glass articles to India. These glass articles when
rejected were collected and melted in locally made furnace called as "Bhainsa Bhatti." This was
the start of the glass industry in Ferozabad. In this furnace, wood was used as a fuel. These old
traditional furnaces are still in use in Sasani near Aligarh and at Purdal Nagar.During that time
only small bottles and Bangles were made. At this time only one bangle at a time can be made. In
this bangle there was no joint. These bangles were called as "Kadechhal Ki Chudi."

Since then Firozabad is the home of the glass industry, white and coloured glass pieces being
manufactured for the purpose of assembling, jhad and fanus (chandeliers) which were in demand
by royal courts and nobles for decoration their assembling and drawing rooms later on phials for
Itra , Scents and other cosmetic products were made. Slowly and steadily Indian marriage items
like bangles, kangans, kada etc. were produced in bulkfor the general public.Today it is
nicknamed suhag nagri because it fulfils almost all the demand of bangles, kadas, kangans and
other items of suhagins(married women).

Since 1989, Firozabad started production of artistic glassware in different colours and shades
used in chandeliers and other items. About four hundred glass industries are registered in
firozabad, these are making different types of glass product. They are using natural gas instead
of coal. The 50% production of these units are exported to different countries. Now-a-days,
blowing/modeling is done by the pot regenerative tank furnish process in the factories.

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 CHAPTER-2

Process

Glassware manufacturing process in the city is following

the old traditional methods. As a raw material for the
process, sand (silica) and soda is mixed in a fixed
proportion along with waste and rough glass, then the
mixture is poured in the furnace for melting it. The role of
Soda in the mixture is of catalyst. It helps in decreasing
the melting point of Silica.

Artisans taking out the molten glass from the

furnace

The molten mixture prepared with the

above method is glass.Molten glass is
then taken out from the furnace with
the help of iron pipes. The glass
worker then blows air through their
mouth from the other end of pipe and
the molten glass, which is on the
second end of the pipe, blows like
balloon. Before this blown glass cools,
it is quickly placed in the dyes of
desired size and shape.

Artisans skillfully blowing the molten glass with the help of iron rods

As the glass cools it takes the shape of that dye. Thus the raw glassware is ready, which is then
sent to a heater with a conveyor belt. Here the glassware becomes hard and strong.

Dye is a very important component for making glassware. In Ferozabad there are various
separate engineering units for the manufacturing of dyes. It also required skilled art and
handicraft work. Giving shape and size is the mechanical work, but engraving of grooves and
pattern is a pure handicraft. Artisans engrave designs and pattern as per requirement with simple
tools.

After passing through all the above processes it is now time for the final finishing work. The
glassware prepared with the above process contains the pipe mouthed shape at one end which is
remove by cutting through the cutter made up of simple heater spring connected with electric
terminals. The heated coil very finely cuts the glass. Some big units are using automatic
machines for cutting. After cutting, the edges are smoothened through burnishing. Then comes
the term of polishing, colouring, coating or drawing of various designs. This is the work of
decoration for which there are separate units in the City. The coloured glasses are made with the
use of certain chemicals, which are added to the mixture of sand (silica) and soda before putting

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it into the furnace. Chemicals like Cobalt which gives blue colour, cadmium for yellow, Zinc oxide
for green and Arsenic, Sodium cyanide etc. are used as per the requirement of colours.

Another type of glass, press glass is also manufactured in some units. Its process of
manufacturing is also simple. Molten mixture is pour into dye of desired shape and size. Then it is
hardly pressed with an automatic press machine. After this, it is sent for heating to make it strong.
Generally plates, candle stands and few kind of glasses are made with this process.

Finishing and Decoration of glassware

The manufacturing units almost prepare the basic glassware but it's the job of decoration
department to make the product as impressive and beautiful as possible. This part of job needs
highly creative cult of mind. Painting vivid colours, innovative patterns, etc., as per the demand of
market or customer is the responsibility of this department.

For giving any particular shade to the glass article, paint mixed with certain chemicals is sprayed
over it. Permanent coloured glasses are usually prepared through furnace only, by mixing the
required chemical in raw material.

For giving silver shade, silver coating is done on it.In this process, the article is washed many
times. First with Hydro-floric acid, then with water and then again with 'Tin' water. After that a
mixture of "Glucose, Sodium, Potassium and Silver along with Spirit and one other chemical
locally called as Chapada is coated on the glass article. This on drying gives silver shade to
glass.

There are various other techniques to give different look to any glassware; 'Etching' is one of
them. For making this type of glassware, sand is blasted on the heated glass with very high
pressure, giving rough look to the outer surface of glass. Similarly for giving a look of "Cracked
surface" heated molten glassware after putting in dye is immersed in water and quickly removed
from it within seconds. This sudden change in temperature gives cracks on its surface.

Decoration of glassware is done in many ways, fitting of other material on it is one of them. But
any sort of fitting work on glassware is not available in Ferozabad. Iron fitting, brass fitting or
wood fitting etc. is done in other cities like Moradabad.

BANGLES

Process of manufacturing of bangles is also quite similar to the above-described process in the
initial stage. Raw glass for bangles is the same material prepared for other glasswares, which is
taken out of the furnace through the similar pipes. Without removing the pipes, the molten glass is
beaten to make its dimensions equal (Chaurus).

After this, the glass with the pipe is placed in an another furnace with an automated roller. When
this molten glass comes in contact with the roller, it starts stretching like a thread and rolls around
it. Like this spring of glass is formed. This spring is then cut through the cutter of diamond making
separate bangles. These bangles have two ends, which need to be joined. It's the job for
separate units. These bangles are given to the contractor, who takes the material to the workers
for the joining process. It is termed as Judai. Then the joined bangles pass through another
process called as Sadhai. It is the process of making the joints neat and straight. Women workers
generally accomplish this job.

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A large number of people in the city
are engaged with the work of Judai
and Sadhai to earn their livelihood.
These processes in itself forms
another industry in the city. It is
again the work of fire and glass and
very interesting set-up is used for it.

Skilled hands of artisans doing the Sadhai work

on bangles

Workers doing joining or Judai uses simple chimney of kerosene connected with the air input,
generated by simple air compressor, locally artisans call it as Pankha.In one unit almost 15 to 20
chimneys are connected with one air compressor. Whole of the set-up is hand made. In some
units condoms were used as an air bladder in the chimneys which were connected with the
compressor. For joining the ends of bangle, it is suspended over the flame. As the glass melts,
application of little pressure joins both the ends.

TThis joining process left the bangles bit out of shape, thus it need the work of Sadhai. The joined
bangles are then send to this department, which is generally handled by women workers. For
Sadhai an aluminum pipe, with equidistant pinholes, is connected with the LPG cylinder. his pipe
is closed from other end.This hand made stove is ignited giving multiple flames on a single pipe.
This allows working many workers with a single gas cylinder, depending on the number of holes
on the pipe. This pipe is placed on the edge of a big platform, which helps in making the joints
symmetrical. The bangles are again kept on the flame. As the glass softens, bangle is pressed on
the platform making it symmetrical.

Decoration work on bangles

Now it is the turn of decoration on the bangles.

Usually a bangle before coming in the market
passes through almost ten to fifteen hands. For
decorating a bangle there are several ways
depending upon the requirement of design
etc.For example, to make a Kada (a type of
bangle)sometimes, several bangles are joined
together

Women doing decorative work on the bangles

through melting over a flame, then with the help of a thin glass stick, designs can be drawn on
it.The burner used in this work is the same as described before. Sometimes, engraving is done
on the bangles. This work is usually accomplished with the help of rotating grinders.

For giving different colour shades to a bangle, various other processes are involved. Like, for the
coating of Zari, hardener and resin is mixed in equal quantity, making a paste, which is then
applied on the bangle. After this, the bangles are collectively rolled over the Zari powder. To give

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a colour to a white bangle, colour is sprayed over the bangles through air compressor. Mostly
young girls are involved in these jobs.

GLASS TOYS

The process of glass items manufacturing

is quite simple in terms of technology
used in it. Small artisans manufacturing
glass toys and other decorative items buy
simple borosil glass, lead glass or the
soda glass depending upon the
requirement of colour etc. for raw
material. The set-up they are using is a
simple gas burner with two inputs in it.

An experienced artisan making small glass toys

with the help of a burner

One for LPG and another for air, which is used to give the required pressure to the flame, so as to
melt the glass properly. The temperature of the flame reaches upto 3000 degree centigrade,
which is very appropriate for the glass to melt. Almost no other tool is used in the entire process
except very occasional help of 'player' or 'plucker.'

Some artisans in the out skirts of the city use kerosene inspite of LPG. Their set-up is bit different
from that of LPG. With kerosene, a chimney is ignited, and then air is pumped through a hand-
made air bladder. Artisans have to continuously pump the air through their leg while preparing the
glass article, which give the required pressure to the flame.

Artisans usually prepare this set-up at their homes. Room of 10 ft by 6 ft with a 40-watt bulb over
the head is enough for it. Giving any shape to the glass rod is quite easier for a skilled artisan. As
the glass is placed on the flame, it starts taking the shape of the imagination of artist. Special care
has to be taken while preparing the article so that the artist always has a place to hold the heated
glass on flame, because they do not use any holder for that. The process of making an art piece
has to be continuous. It takes from five to twenty minutes to complete an art piece.

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 CHAPTER-3

Products

All sorts of glass articles viz. jars, candle stands, glasses, flower vases etc. including electric
wares like decorative lights, bulbs and every other sort of glass articles are prepared in this city.
These articles are painted with vivid colours and innovative patterns. Etching is done on some
products to enhance their beauty. Decoration work is also done on some products by fixing other
material on them.

Firozabad glass industry broadly consists following types of products: -

Glass Artwares
Glass artware like toys, candle-stands, crosses, Christmas trees, different fruits, mini-trees,
images of birds, animals, personalities, Gods and Goddesses are made here for Indian as well as
foreign markets. These products are wonderfully beautiful and are so perfect that nobody can
imagine that these are made by bare hands of the artisans.

Glass Domestic-wares
Firozabad glass industry for the last two centuries has been involoved in manufacturing drinking
glasses, beer glasses, wine glasses, dinner sets consisting of bowls, plates, lemon-sets, pudding
sets, etc. in attractive cuttings, charming designs.

Glass Chandeliers
Since mughal period Firozabad has been producing different shapes and shades of magnificent
hanging chandeliers. Many innovative designs have been added to suit different tastes.

Glass Marriagewares
Bangles, Kangans and karas are made here since ancient period as traditional Indian woman
wadrobe accessory. Bangles made here are distributed throughout India. Bangles don't get that
much opportunity in the international market, since it is a traditional Indian accessory. But still due
to globalisation the market for bangles is expanding internationally.

Glass Hard wares

All types of glass hardwares are manufactured here for house decoration and other purposes.

Glass Scienctific and Lab wares

Since last 10 years beakers, flasks, test tubes, containers and other scientific wares are being
manufactured here, which are needed in various laboratories.

Glass Automobile wares

The glass accessories for automobiles like light bulbs, mine battery bulbs and other light and
sight equipments are produced here for two wheelers and four wheelers.

Glass Street and domestic light wares

For the lighting of urban and rural areas and other utility purposes many glass items are being
produced including miniature bulbs and high power voltage bulbs. It is estimated that 6% demand
of bulbs is being fulfilled from Firozabad.

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 These beautiful handcrafted flower
vases shows the expertise and
creativity of the artisans who have
manufactured it.
These kinds of vases are one of the
specialities of Firozabad. Anybody
could fell in love with these pieces
of art.

Different types of Flower Vases

The glass toys made here are hand crafted and the
sheer genius of the artisans making it is reflected in the
magnificence of the products. The artisans making
these toys are so much skilled in this art that they can
prepare a toy piece within minutes.

The glass toys of Firozabad has great international

demand and people throughout the world loves these
toys. One more small glass item which is particularly
popular in India are the idols of the Gods of Hindu
mythology.

Glass Toy - Giraffe

Another very important product of Firozabad is Bangles.

Firozabad bangle industry is the most famous industry in
India for bangles. Bangles are one of the important most
traditional wardrobe accessories for an Indian married
woman. These are wore by them on their wrist.
One of the important fact about bangle industry of
Firozabad is that mostly women are engaged in the
manufacturing of bangles. They put all their hardwork and
creativity in designing these bangles.

A chain of bangles

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 CHAPTER-4

ISSUES@GLASS INDUSTRIES

The objectives listed below pertain to the glass industry cluster at Firozabad .

• Standardisation and testing of raw materials

• Cost effective utilisation of raw materials and
energy sources.
• Research and development activities for
upgrading the technology
• Skill development through training, and
• Reduction in thermal and chemical pollution

These objectives were modified in the course of the time by various efforts of
Govt. & NGOs and finally have been converted to the following:

• Providing analysis facilities for the glass

industry
• Acquiring, mastering and feeding back to the
local industry, appropriate technology on:

* Furnace design and construction

* Furnace operation
* Pot formulation and making
* Mould design and making
* Glass formulation
* Alternative methods of production

Problem areas

Firozabad is a city whose population of half a million solely depends on the local
glass industry. Unfortunately, the industry they depend on is primitive and
inefficient. The immense quantity of labour put in can produce a very low
quantity of added value. Consequently, income and life standard of the workers
in the area is very low.

The furnaces used by the industry are modified forms of a Japanese design,
which has been acquired many decades ago. They have been modified without
understanding the basic design. Therefore, the change has been for the worse,
decreasing the furnace life and fuel efficiency.

Expected end of prevelent situation

As a consequence of the improved technologies, fuel efficiencies, production

efficiencies furnace and pot lives would increase, in turn, enabling the producers
to produce higher quality products at lower costs and with less effort.
Subsequently, the living and working standards of the Firozabad people would

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improve owing to increased incomes improved equipment and cleaner
environment.

The position of the industry and the intended end of project situation were
expected to be as follows:

• Energy Efficiency

By re-designing the glass furnaces in the area, their energy consumption should
be decreased by at least 20%. Simple energy recovery systems would decrease
the energy usage by another 15%.

• Technology Transfer

Know-how on mainly the following subjects should be compiled and made ready
to be presented to the industrialists.

* furnace design and construction,

* pot formulation, production and preheating,
* mould design and production,
* glass formulation,
* glass forming and annealing
* glass decoration by colouring sanding and cutting
* acid polishing

• Pollution
Owing to the reduced fuel consumption and efficient combustion, atmospheric
pollution in the city and the area shall be cleared. Better
handling of the raw materials shall decrease, if not eliminate solid pollution of the
environment.

• Industry Linkages
Most of the technologies adopted and tried in this area shall be transferred to the
glass industries in other parts of the country.

• Financial viability
When totally accepted by the local industry and fully operational, provided that
the industry is willing to pay the actual cost of the services they get, the centre
can be self sufficient and even profitable. But during the initial years and until
the centre gains the required acceptance, they shall have to be supported
financially.

• Testing
In CDGI a fully equipped laboratory is to be set-up. This laboratory should be
able to make the following:

* Full chemical analyses of glasses and glass raw

materials
* Determination of the physical properties of glasses
* Full chemical analyses of pot bodies and pot raw

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 materials
* Determination of the physical properties of pot
bodies and pot raw materials
* Stack gas analyses
* Identification of solid glass inclusions

• Training
CDGI / CII / NGOs would be able to offer specialised courses. The courses shall
cover short-term seminars for the industry and long term courses for the
workers in the city. The present training facilities in the city is to be called
“Women’s’ Training Centre ” and is to be allocated mainly to increasing the
capability of women in the home based glass processing and finishing operations.

• Information and Consultancy

CDGI/ CII / NGOs would be equipped to provide consultancy services and up-to-
date information in response of industry needs. They would also take up projects
to make research for solving industrial problems.

Library of the centre shall be open to all members of the industry.

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 CHAPTER-5

Technology Improvement Programme

The Firozabad glass cluster, located close to Agra, accounts for 70% of glass
production in the SSI sector. These glass furnaces are highly energy-intensive and
employ designs that are inherently inefficient. Based upon a diagnostic study, two
types of furnaces: pot furnaces (used for glass melting) and muffle furnaces (used
for bangle baking) were identified for further intervention. This intervention is being
carried out in the backdrop of the judgement passed by the Supreme Court of India,
which mandates the glass factories located in Firozabad to switch over from coal to
natural gas. The directive was aimed at reducing environmental pollution on account
of industrial activity in the Taj Trapezium zone.

This area has demonstrated a gas-fired pot

furnace with heat recovery system in the
cluster. About 50% reduction in energy
consumption was achieved compared to
traditional coal-fired furnaces. The Centre is
also engaged in developing energy-efficient
gas-fired muffle furnaces with the aim to
replace existing coal-fired units.

A view of the gas-fired pot furnace

Cluster modernization programme for Khurja pottery units

A diagnostic study was carried out for Khurja pottery units with the objective of
improving the manufacturing process. The study has identified problem areas in
different production processes and technologies, and suggested remedial measures.

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