Central Tool Room Ludhiana

Ministry of Micro, Small and Medium Enterprise, Govt. of India Society

A-5, Phase-5, Focal Point Ludhiana 141010

Framework for proposal for setting up Centre of Excellence for Agro Research Units
in Technology Centres:

1. Name of the Organization: Central Tool Room, Ludhiana

2. Complete Address: A5 Phase 5, Focal Point, Ludhiana 141010

CTR Extension Centre, GT Road Nilokheri -132117, Karnal (Haryana)

Ph: 9416303789, 8568073457

3. Website:www.ctrudhiana.org

4. Vision, Mission & Objectives:

 To increase the efficiency of small-scale units in the Northern Region in light

engineering and allied fields by providing support in the design and production
of tools and jigs & fixtures as well as by rendering technical consultancy services
 To manufacture small and medium-size tools such as press tools, jigs & fixtures,
moulds, dies, and special purpose tools
 To provide common service facilities to small-scale industries regarding the
manufacture of various types of tools, heat treatment, and related services
 To impart long-term technical training in the form of Diploma, Certificate course
in Heat treatment and Condensed Courses to students who want to become
toolmakers, technicians in the plastic and metal processing industry or heat
treatment specialists
 To conduct short-term and part-time courses for technical staff of small-scale
industries putting emphasis on advanced technologies such as CNC
programming and machining and CAD/CAM, but also offering training in
conventional subjects

5. DPR for Following Project

Sr. No. Project Name

01 Lemon Grass Project
02 Laser Cutting
03 Bangle Straightening & Joining Machine
Project 01: Lemon Grass Project
01. Model of CoE: Hub & Spoke with hub at CTR Ludhiana and spoke at CTR Extension
Centre situated at GT Road Nilokheri -132117, Karnal (Haryana)

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

02. Details of spare land/area available:

CTR Ludhiana is built on a land of 7.5 acre with constructed area of

CTR extension Centre Nilokheri is situated at Nilokheri, Distt- Karnal , Haryana on NH-1 (Delhi –
Chandigarh Highway ).

The centre acquires a land of 13 acres out of which approximate 7 acres of spare land is available,
which can be utilised for developing a full flashed Centre of Excellence for Agricultural sector of
Karnal.

03. Equipment available: CTR Extension Centre is Equipped with lots of industrial Equipments to
provide service to industries of nearby areas. Details are as follows:

CNC Machine :
CNC Lathe machine 03 Nos
1.
CNC EDM Wire-Cut 01 Nos
2.
CNC EDM Die Sink 01 Nos Proposed
3.
CNC Milling Machines 03 Nos PO Placed
4.
Conventional machines:
1. Shaper Machines 01 Nos
Pedestal Grinders 03 Nos
Drill Machine 04 Nos
Welding laboratory
Arc Welding 05 Nos
1.
TIG Welding 05 Nos
5.
MIG Welding 05 Nos
6.
Plasma Cutting 01 Nos
7.
Pug Cutting 05 Nos
8.
Laser welding Machine 01 Nos
9.
Plastic Welding 01 Nos
10.
Brazing Torches 05 Nos
11.
Heating Torches 05 Nos
12.
Cutting Torches 05 Nos
13.
Chop Saw 02 Nos
14.
Hand Grinders 13 Nos
15.
Portable Drill machine 01 Nos
16.
CAD/CAM facility available
Desktop Workstation 35 Nos AutoCAD/ NX/ Soldworks/
1.
MasterCAM/ SolidEdge/ Creo /

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

Catia Design software available

Desktop Computers 50 Nos
2.
(High End)
Heat Treatment Facility Available
1. Vaccum Furnace 01 PO Placed
Plasma Nitriding 01 Tender placed
2.
04. Vehicles available: 2 nos as per the following

05. Details/ Profile of personnel employed:

Sr. No. Name Designation Qualification Experience

1. Anoop Kumar Engineer Training B. Tech ( mechanical) 10 year experience
in CTR Ludhiana
Training
2. Aman TG-III B.tech (Mechanical ) 3 Year experience in
CTR Ludhiana
3. Shiv Kumar TG-III Diploma (Mechanical) 07 year experience

06. Need of CoE in Area

Extension Centre Nilokheri, Distt.Karnal:

Extension Centre Nilokheri is an outreach centre of Central Tool Room, Ludhiana
established in year 2014-2015. Currently it is being operational at GT Road
Nilokheri.
Nilokheri is a small town which is located in Karnal District of Haryana. It is
situated on Delhi-Chandigarh national Highway, 123 kms. from Delhi. The
Extension Centre has built up area of approximately 10,000 sq.ft.
PRODUCT INTRODUCTION:
Lemongrass oil has a strong lemon-like odour due to high citral content (75-90%).
The minimum commercial requirement is 70% citral content. The major quality
checking measures are its citral content and its solubility in alcohol. This is an
essential ingredient in toiletry products such as toilet soaps, bath salts, etc. It is also
employed in artificial lemon flavouring and in the manufacture of ionenes. Ionenes
are very important for the production of artificial flavour, perfumes, and soaps and
as raw material for vitamin A manufacturing. Here in this project, we intend to
explore how to start a small-scale lemongrass oil manufacturing business. The oil is
of a reddish-yellow to reddish-brown colour, with a strong, lemon odour. It is also
used in pharmaceutical preparations, such as pain balm, disinfectants, and mosquito
repellent cream. Oil is the source of Citral which is used as a basic raw material for
synthesis of Beta-ionone used for synthesis of a number of useful aromatic
compounds and Vitamin-A. This is thus used as substitutes of ‘cod liver oil. Citral
itself is used in perfumery for various grades of soaps, detergents, cosmetics and
flavour agent for soft drinks.

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

MARKET POTENTIAL:
The growing demand for lemongrass is stimulated by its therapeutic benefits such as
for antifungal, anti-antiseptic, anti-inflammatory properties. Growing awareness of
the therapeutic benefits of essential oils has spurred the utilization of lemongrass for
commercial use in personal care industry and food industry. Asian nations have seen
rise in commercial production of lemongrass. Rise in adoption of lemongrass oil in
aromatherapy is a key trend bolstering the production of lemongrass oil. Growing
popularity of aromatherapy for therapeutic end is also boosting the prospects in the
lemongrass market. Producers in the lemongrass oil market are seeing resurgence of
interest among companies who specialize in plant-based therapeutic grade products.
Numerous stakeholders in the past few years have been leaning on integrating the
value chain in a bid to make frequent product innovations. They are collaborating
from the raw material producers to sellers to gain a large pie in the global
lemongrass oil. Further, numerous cosmetics and pharmaceutical companies have
been increasing their stakes among essential oil producers. This has also spurred
investments in the lemongrass market. In the coming years, they are expected to
play a key role in shaping the competitive contours, especially during the forecast
period of 2020 – 2030.
RAW MATERIAL DESCRIPTION:
The major raw material is lemon grass. And the grass plants grow well in soils not
suitable for richer production plants. From sandy and rather dry soils yield relatively
more oil and oil of higher citral content than plants from very fertile soils.

PROCESS FLOW CHART

A primitive processing is already included in harvesting which includes partial
cleaning, packaging and sorting of required part of crop but oil extraction takes it a
step further and extracts the required oil out of the harvested crop. This is essentially
true for aromatic crops which may lose the essential oils after a particular period of
harvest. For aromatic plants this primary processing includes pre-process of Field
Distillation and Field Distillation itself. The field distillation unit consists of a Heating
Tanks, Furnace, Condenser, Water Pump, pipings and a separator, these components
are basic components of field distillation unit though extra part may be required for
more through processing or oil extraction. The pre-process simply includes cleaning
of required part of crop in a large washing tank, if it’s in contact with soil or close to
soil. Then the next step is simple which is a simple steam distillation process, The
required part of aromatic plant is heated with steam generated by boiling water in
heating tank, during this process the steam generated carries along with it aromatic
oils. This steam is transferred to condenser via steam pipe, as condenser is circulated
with cooling water continuously, thus steam transferred to condenser undergoes
condensation as water and aromatic oil have different boiling point they get
separated completing distillation process. The contents (Water + Aromatic Oil)
obtained from condenser are supplied to separator which is designed for extraction

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

of a particular range of oil. The liquid is allowed to settle down and as oil and water
are immiscible, they both separate into layers, water is drained from separator and
supplied back to heating tank; entire process is repeated for enrichment purpose.
The enrichment process continues till most of the aromatic oil is extracted, followed
by which oil is sold in market after packaging in appropriate containers, while
remains of aromatic part of plant are usually supplied or sold to Incense Stick
Makers.

Procurement of Raw material

Cleaning

Feeding to Heating
Tank

Distillation

Oil Separation & Extraction

Oil Filling & Packing 5

 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

PROBLEMS TO BE ADRESSED
 Extraction of lemongrass oil and its sale can be taken up as one of the best
suitable livelihood programme for providing livelihood support to the poor
farmers.
 Unutilized waste land of farmers can be best utilized as sustainable livelihood
support by cultivation of lemongrass which is a rain fed crop requiring very
less irrigation and with little maintenance.

Planting Materials

 Lemon Grass slips are used as planting material for plantation of lemongrass.
 As there is no Govt source of planting material, the planting
materials will be collected from the farmers, who have already
done plantations. The price will be approved by the Technical
Committee.
 For each 1 acre of lemongrass plantation, 20000 nos. of slips would
be required for planting at a spacing 45 cm x 45 cm.

AIMS AND OBJECTIVES:

 To increase the area under lemon grass cultivation.
 To make unproductive land to productive one.
 To introduce new and improved cultivars.
 To popularize non‐traditional cash crop to improve socio –
economic status of poor farmers and assured income to the
farmers in a long run.
 To make a lemon grass hub for the national and international
market.
 To facilitate farmers and buyers interaction for better marketing

Cultivation
 Lemongrass Oil is used in the perfumery and cosmetic industry and the
Oil (Citral) is extracted by steam distillation process.
 Yields per acre is 50 Ton of grass per Annum in 4 cycles.
 Oil Extraction rate is 0.6% to 1% i.e. from 1 acre of land we will get
minimum 200 kg of Citral @ Rs. 1500/kg = Rs. 3.00 Lakhs.
 Once planted can be harvested up to 7 years.
 Number of plants per acre = 20,000 nos. (1.5ft x 1.5ft)

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

 A Distillation Unit of capacity 1MT/day can be run for 300 days in a year
.

Technical specification of processing unit

The extraction of lemongrass oil is done by a steam distillation process.
Regional Research Laboratory, Jorhat had developed the technology for the
same. The main raw material required is lemon grass, apart from fuel and water
for the distillation process. The percentage of oil is as low as 0.6%. Little
overheating or improper condensing may result in very low output and would
damage some of the delicate aromatic components.
The distillation process comprises of two units, the tilting type distillation still
and the condenser. The distillation unit is connected to the condenser through
a pipe at the top. The condenser is a wild copper tube, which is cooled by
flowing water. The condenser is connected to the oil accumulators.
First distillation unit is filled with water up to the desired level over which the
grid is placed. Lemon grass collected from the field are then filled in the still
over the grid and the lid is closed. The lid must be airtight. The still is then
heated with the heat source provided below the still. The type of heat source
depends on the fuel availability. Oil and water vapour mixer flowing out of the
still passes through the condenser. The mixture gets cooled in the condenser
and condense. The mixture of water and oil is collected in the accumulator. The
oil is then separated from water as per the specific gravity.

Academic Institution in Area:

Sr. Name of Institution Courses offered

No.
1. Govt. Polytechnic Nilokheri Diploma in Mechanical/Civil/Computer Science/
Electronics/ Electrical Engineering
2. Govt. Engineering College Nilokheri B.tech in Mechanical/Civil/Computer Science/
Electronics/ Electrical Engineering
3. National Institute of Technology B.tech in Mechanical/Civil/Computer Science/
Kurukshetra Electronics/ Electrical Engineering
4. National Institute of Design Kurukshetra B. Design in Product / Textile/interior Design
5. National Institute of Electronics and A-level , O –level , B- leve computer courses, VLSI
Information Technology Kurukshetra Design ,
6. Govt. Polytechnic Kurukshetra Diploma in Mechanical/Civil/Computer Science/
Electronics/ Electrical Engineering
7. Govt. ITI Karnal ITI in Machinist/Turner/ Fitter/ Draftsman/
welder/ COPA/ Plumbing/ Tractor Mechanic/
diesel mechanic
8. Govt. ITI Kurukshetra ITI in Machinist/Turner/ Fitter/ Draftsman/
welder/ COPA/ Plumbing/ Tractor Mechanic/
diesel mechanic
9. Govt. ITI Yamuna Nagar ITI in Machinist/Turner/ Fitter/ Draftsman/

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

welder/ COPA/ Plumbing/ Tractor Mechanic/

diesel mechanic
10. Maharana Pratap horticulture University B.Sc Horticulture (4 years)
11. Haryana Agriculture University Hisar B.tech/ B.Sc in Agriculture Engineering
10. Centre of Excellence is suitable at Tool Room Extension Centre Nilokheri:
Suitability for:

S.No Particulars Details (Existing) Additional ( proposed for CoE)

Physical infrastructure: CAD/CAM Lab , Lemon grass Farming and Oil
Machine and Welding extraction Unit
Workshop
Availability of Land for CoE 7 acres spare land No additional land required
Availability of building/Shed for Not available Building/Shed to be constructed
A
CoE / renovated
Availability of hostel facility for Available with 35 Dormitory available for
CoE student capacity renovation which will increase
the capacity by 60 students

Human Resources
Core qualified technical staff for 01 03
CoE
B
Operating staff 03
Trainers 03 01

Capability for providing high Tool design, welding, Lemon grass farming
quality technical training in area CAD/CAM and CNC
C
of excellence

Association with Industry and 05 nos of MoUs with MoUs may be signed with
Academia( number of MoUs Academic institutions Horticulture university Karnal
/Agreements with Industry, of the area FFDC Kannauj to be associated
D
Academic Institutions, Research as professional expert
bodies etc)

Accreditation/ Recognition of NSQF

F courses

Targeted beneficiaries Technical Institutions Beneficiaries will be farmers of

like Diploma/B.tech Karnal, Panipat, Kurukshetra
and it is of the region Region and students of
G and skilled personnel Hotriculture university Karnal.
from Manufacturing
Associations like
KAIMA, ASIMA

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

Identified focus areas for CoE The main focus area Centre of Excellence will Focus
of the centre is on educate people on Lemon
technical training in Grass Farming and Oil
the field of Extraction which will be great
H
manufacturing for boost to Entrepreneurship in
students and nearby areas.
unemployed youth in
the catchment area.
Envisaged activities Promoting Techniques of
Lemon grass Farming
I NIL Lemon Grass Oil extraction
Educating farmers on Lemon
grass farming

CAPEX and OPEX: for 4 years or duration of RAMP programme

Capital Expenditure CAPEX:

1. Lemon grass farming and Oil Extraction Unit

Sr. No. Expenditure head Cost

1 Construction of Shed for distillation unit and 50 Lacs
storage of lemon grass of size 8 x 5 x 4.5 m
2 Distillation Unit of 1 MT capacity 20 lac
3 Water supply arrangement (Bore well, pump and 2.5 lac
irrigation system )
Total 72.5 lacs

1. CNC Laser Cutting Machine :

Sr. No. Expenditure head Cost

1 Construction of Shed for CNC Laser Cutting 5 Lacs

Machine

2 CNC Laser Cutting machine ad its Accessories 60 lac

3 Installation 1.0 Lac

Total 66.0 lacs

Total CaPEx = 66.0 + 72.5 lacs = 138.5 lacs

Operational Expenditure:

1. Lemon grass farming and Oil Extraction Unit

Sr. No. Expenditure head Cost (1st year) 2nd year 3rd year 4th year
1 Land preparation 0.20 lac 0.20 lac 0.20 lac 0.20 lac

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

2 Cost of seed/sapling 2.0 lac 0 0 0

3 Cost of plantation 0.20 lac 0.20 lac 0.20 lac 0.20 lac
4 Cost of fertilizers and compost 0.25 lac 0.25 lac 0.25 lac 0.25 lac
5 Cost of harvesting @ 4 times a 0.50 lac 0.50 lac 0.50 lac 0.50 lac
year
6 Distillation cost 0.60 lac 0.60 lac 0.60 lac 0.60 lac
7 Packaging cost 0.10 lac 0.10 lac 0.10 lac 0.10 lac
8 Energy cost 1.5 lacs 1.8 lacs 2.1 lacs 3 lacs
9 Maintenance, AMC for 1 1 1 1
machines, equipment
10 Stationary, publicity, Travel, 1 1 1 1
telephone, transport,
hospitality and other
overheads
11 Professional Expert fee, 2 1 1 1
consultant fee, etc
12 Workshops/awareness 2 1 1 1
programmes and other office
administrative expenditure
Total 11.35 lac 7.65 lac 7.95 lac 8.85 lac

2. CNC Laser Cutting Machine :

Sr. No. Expenditure head Cost (1st year) Cost (2nd year) Cost (3rd year) Cost (4th
year)
1 Electricity 1.20 Lacs 1.20 Lacs 1.20 Lacs 1.20 Lacs

2 Consumables 2.40 lac 2.40 lac 2.40 lac 2.40 lac

3 AMC for machine 0 6.0 Lac 6.0 Lac 6.0 Lac

Total 3.60 lacs 9.60 lacs 9.60 lacs 9.60 lacs

Salary and manpower requirement

Sr. No. Designation No. of post Salary (month) Annual 4 years

1. Supervisor 1 0.25 lac 3.0 lac 12.0
2. Maintenance engineer 1 0.25 lac 3.0 lac 12.0
3. Operator 1 0.2 2.4 9.6
4. CNC laser Operator 1 0.2 2.4 9.6
Total 43.2 lacs
Total OPEX for 4 years = 35.8 lacs + 43.2 lacs+ 32.4 lacs = 111.4 lacs
Total project Cost for 04 Years: CAPEX + OPEX = 138.5+ 111.4= 249.9 lacs
Expected Outcomes:
Training:

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

Year Number of Number of MSME Units Assisted Estimated Revenue (Training &
Trainees with placement Production) (in Lakh)

Year 1 150 10 15
Year 2 200 25 20
Year 3 250 40 25
Year 4 300 60 30
Total 900 135 90

Revenue from oil extraction

Total oil produced from 1 acre = 200 kg

Average price of 1 kg of oil = Rs. 1500/ kg

Total revenue for 1 year = 3.0 lacs per year

Total revenue for 4 years = 12.0 lacs

Expected Revenue for 4 years

Sr. No. Training Services Essential oil

1st year 15 5 3.0 lacs

2nd year 20 8 3.0 lacs

3rd year 25 10 3.0 lacs

4th year 30 15 3.0 lacs

Total 90 lacs 38 lacs 12.0 lacs

Processing farmers’ output

Sr. No. Oil, Kg Essential oil , Rs.

1st year 1000 15 lacs

2nd year 1200 18 lacs
3rd year 1400 21 lacs
4th year 2000 30 lacs
Total 5600 84 lacs

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

Total revenue = 224.0 lacs

Net Profit = Total Revenue – Total Expenditure = -25.9 lacs

Project 2: Bangle Straightening and joining Project at CTR Ludhiana

01. Equipments available: CTR Ludhiana is having the following machines and equipment installed
at the premises.

Sr.
CNC MACHINE DESCRIPTION MAKE/ MODEL Quantity
No

1. CNC MILLING MACHINES (VMC) 13

2. CNC MILLING MACHINES (HMC) 01

3. CNC LATHE 07

4. CONVENTIONAL LATHE 17

5. 5-AXIS CNC MILLING WITH SWIVELLING ROTARY TABLE 01

6. CNC CYLINDRICAL GRINDING 01

7. CYLINDRICAL GRINDING CONVENTIONAL 06

8. GRINDING 13

9. JIG BORING MACHINE 01

10. JIG GRINDING MACHINE 01

11. EDM WIRECUT 06

12. EDM 04

13. DRILLING MACHINE 15

14. SHAPER 05

15. PRESSESS 07

16. INJECTION MOULDING 02

17. CO-ORDINATE MEASURING MACHINE-CMM 01

CARL ZEISS (PRISMO 5, HTG VAST) WITH DIGITIZING AND REVERSE

ENGINEERING CAPABILITY

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

18. PROFILE PROJECTOR 01

19. HEIGHT MASTER –DIGIMAR 817 CLM (MAHR) 01

20. WHITE LIGHT SCANNER 01

21. Vacuum furnace 01

22. Salt bath Furnace 02

23. Plasma Nitriding 01

24. Furnaces 05

25. Spectroscope 01

26. Universal hardness Tester 01

CAD/CAM facility available

Desktop Workstation 50 Nos AutoCAD/ NX/ Soldworks/
0 MasterCAM/ SolidEdge/
1 Creo / Catia Design software
available
Desktop Computers (High End) 240 Nos
0
2

02. Vehicles available: 2 nos. as per the following

1. PB10HH1163 (Multi Utility Vehicle)

2. PB10FV5442 (Light Commercial Vehicle)

03. Details/ Profile of personnel employed:

The detail of regular staff at CTR Ludhiana is as below:

No. of
S.N. Group Level Posts Fill
Name of Post Sanctioned
up
1 General Manager A 13A 1
2 Dy. General Manager A 13 0
3 Sr. Manager A 12 0
4 Manager Consultancy, Training & Prod. &
Design A 11 2
5 Manager Heat Treatment A 11 1
6 Manager Administration A 11 0
7 Asstt. Manager Training, Prod., Consultancy &
Marketing A 10 1
8 Asstt. Manager Design & Quality Assurance A 10 2

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

9 Asstt. Manager Heat Treatment A 10 0

10 Asstt. Manager (Admn./Accounts) A 10 0
11 Engineer B 6 8
12 Foreman B 6 0
13 Asstt. Admn. Officer B 6 1
14 Asstt. Accounts Officer B 6 0
15 Asstt. Purchase Officer B 6 0
16 PS-GM B 6 1
17 Technician Grade - 1 C 5 8
18 Sr. Store Keeper C 5 0
19 Librarian Cum Clerk C 5 0
20 Stenographer C 4 0
21 Upper Division Clerk C 4 0
22 Technician Grade - II C 4 13
23 Technician Grade - III C 2 16
24 Lower Division Clerk / Receptionist Cum
Telephone Operator C 2 4
25 Driver C 2 1
26 MTS C 1 2
27 Hostel Attendant C 1 1
TOTAL 62

04. Need of CoE in Area

Central Tool Room is situated in Ludhiana, Established in 1980, we represent
Technical Co-operation between Government of India and Government of
Germany.
Growth and development of the engineering industries depend vitally on the
availability of precision tools such as press tools, moulds, jigs & fixtures, and
dies. Those high quality tools & die are manufactured on extremely precise and
computer controlled machines, which are usually not within the reach of small-
scale enterprises. Moreover, these units lack personnel with the respective
expertise.
CTR Ludhiana will support rural industries in setup of Bangle Manufacturing and
also it will provide Technology support to existing manufacturers. Operating in
Ferozabad and other regions.

05. Project Description:

Bangle straightening and joining machines are specialized tools to be used in the
production of glass bangles. These machines are designed to straighten and join glass
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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

bangles, allowing manufacturers to create bangles with a consistent size and shape.
This machine can be used in large-scale production settings, such as factories and
workshops, and can help manufacturers increase production efficiency and reduce
the need for manual labour.

Glass bangle straightening machines works by applying heat to the opposite end of
the bangle joint. This machines typically use mechanical camshaft to apply pressure
to the side of the bangle, allowing for precise control over the amount of force
applied. This machines use a heating element to soften the glass, making it easier to
straighten. Once the bangle is straightened, it can be further processed using a glass
bangle joining machine.

Glass bangle joining machines work by fusing two open end of bangle together to
create a single bangle. The machines typically use a heating element to melt the glass
at the point of contact, allowing the two pieces to fuse together. The machines use a
flame to heat the glass. and the bangle can be further processed as needed.

The use of glass bangle straightening and joining machines can help manufacturers
improve the quality and consistency of their glass bangles. By using these machines,
manufacturers can create bangles with a uniform size and shape, reducing the need
for manual labor and increasing production efficiency. Additionally, the use of glass
bangle straightening and joining machines can help manufacturers reduce waste and
improve overall product quality, resulting in higher customer satisfaction and
increased profitability.

06. Existing Bangle Making Process:

Glass has been known to mankind for thousands of years, which offers utmost level
of flexibility for shaping into different products. Glass bangles are one of the most
common items in Glass products. Bangles are made from glass melted in a tank
furnace with temperatures around 1300 °C to 1400 °C, bangles are made out of soda
glass, Firstly the artisan uses a long iron pole to scoop out a glob of molten glass from
the tank furnace, he then swiftly transfers it to an another artisan who shapes the
glob into a conical shape by rotating the rod and with the help of a customized tool
which looks like a trowel. Then it is transferred to another furnace where Artisans
works in synchronization with the machine, he then draws a thin filament of glass
from the melt and places it steadily on the rotating rod which is constantly rotated
on a motor. The molten glass loops around the rod taking the shape of a bangle,
thickness is controlled by exerting the requisite amount of full on the softened glass

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

these rotating rods comes in different diameters depending on size of the bangle
which is required. Before the molten glob exhausts, next glob is attached to the
previous one to keep continuity. An another artisan who is on the other end of the
furnace uses a metallic ruler/ pointed tool which prevents bangles from sticking to
each other on the spindle and also makes sure that only one layer of glass is rolled
on. When the spindle gets filled up it will be removed, and the glass bangles is taken
out, which looks like a long glass spiral. These spiral are then cut with the help of a
diamond cutter, which separates each bangle from another.

The separated bangles which are open ended and not complete are then taken to
join them over a candle or a kerosene lamp which is called (Judai) which literally
means joining. They melt the bangle slightly to join the ends which are usually done
by women. Bangles are further decorated by zari, silver/golden powder with
different intricate patterns and designs on the surface. The bangles are then finally
baked in a furnace called pakai bhatti which smoothens the sharp edges and makes
the bangles bright and attractive. Bangles are intertwined and strung together,
packed in cardboard boxes to be transported, exported or sold in the market.

07. Problems to be addressed:

The glass bangle making process can be challenging, and manufacturers may face
several problems during production. In the manual bangle making process they
typically consist of a burner or furnace to heat the glass, a mandrel or mold to shape
and size the bangle. The spring shape roll is further processed and by using diamond
cutter they get separated. There are three major process to complete the round
shape of bangle.

1. Straightening Process
2. Joining Process
In conventional method, both of these processes are carried out by local people. In
straightening process where they use LPG as fuel on a metal surface to heat the
bangles and press those with bare hands to straighten each bangle individually then
the bunch of straight bangles are carried to other location where joining process is
carried.

In Joining Process, kerosene lamp with pressurised air is used as fuel, which is very
harmful to inhale which is injurious to health and also creating lot of pollution. The
whole process is time taking due to manual working.

08. Market Potential:

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

Glass bangles are the items of mass consumption throughout the country. The
demand for the glass bangles generally goes up during the festive seasons and
special functions, marriage occasions etc. In spite of competition from plastic and
other bangles, the demand for glass bangles is even increasing in view of established
characterized customary and auspicious status gained by it in the society. Having
very much fragile in nature, the glass bangles have very good replacement demand.
This type of industry is only concentrated in Firozabad manufacturing glass bangles
using pot furnace. This type of industry can be set up in other parts of the country.
These products have very good demand from ladies of lower and middle class
families, there is good scope for setting up new units in this line of manufacture.

The Automatic Bangle straightening and Joining Machine will boost the productivity
and quality of bangles. Also it will help reducing the carbon emission and rural
industry can be befitted from this.

This machine will have huge market potential. There is no such product available in
the market to perform this operation. The bangle straightening and joining process is
already a pain area for existing manufacturer due to its dependency on local manual
industry. Local industries can speed up the production rate by implementing this
machine.

09. RAW Material Description:

The major RAW material in development of this machine is technical equipments i.e.
PLC, SENSOR, FLAME, BURNER, CONVEYOR BELT, MECHANICAL STRUCTURE,
MOTORS, LPG CYLINDER, PNEUMATIC SYSTEM and etc.

10. AIMS and OBJECTIVES:

 Improve Production Efficiency: One of the primary aims of the machine is to

improve the production efficiency of the glass bangle manufacturing process. By
automating the straightening and joining process, the machine can help
manufacturers produce more bangles in less time, increasing their overall output.
 Reduce Labour Costs: Another objective of the machine is to reduce labor costs
associated with the straightening and joining process. The machine can perform
these tasks quickly and efficiently, reducing the need for manual labor, which can
be costly.
 Increase Product Quality: The machine's design and precision ensure that the
straightening and joining process is consistent and accurate, leading to a higher

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

quality finished product. This objective ensures that the bangles are straight,
even, and free of any defects, making them more appealing to customers.
 Reduce Material Waste: The machine's accuracy in the straightening and joining
process can also help to reduce material waste. By ensuring that the bangles are
straight and even, the machine reduces the likelihood of material being discarded
due to defects.
 Improve Workplace Safety: The machine's automation also helps to improve
workplace safety by reducing the need for manual labor in the straightening and
joining process. This objective aims to create a safer workplace for employees,
reducing the risk of injury.
 Increase Profitability: By achieving these objectives, the machine can help
manufacturers increase their profitability by reducing costs, improving production
efficiency, and producing a higher quality finished product that is more appealing
to customers.

11. Technical specification of processing unit: -

Entire process is divided in to three segments Sorting, Straightening and Joining.

Sorting of bangles plays an important role thus an automatic sorting machine has to
be designed to sort the appropriate size (Diameter) of the bangle.

Before going to straightening process one needs to know the condition of bangle
before straightening. The bangle is detached from a spiral structure thus the
detached ends are overlapped on each other. To facilitate joining these overlapped
edges should be brought in front of each other. This process of bringing these edges
in front of each other is called Straightening here.

Straightening is performed by using a stepper motor along with speed reducing gear
box, which helps in rotating the table, over which bangles are placed. A cam is placed
in a calculated way which helps in pulling one of the opened end of the bangle, the
opposite end (Rear End) of the bangle is continuously heated as the flame also rotate
along with the table. Due to heat the Rear end starts melting and at this point table
reaches a station where a cam operated calliper pulls one edge away, resulting in
edges in front of each other causing straightening of bangles.

Joining is Performed by heating opened end of bangle, which are now in front of
each other, heating source is a flame produced by LPG and its timing is controlled by
PLC operated Solenoid valve, after calculated amount of time these opened ends
start to melt, callipers operated using stepper motor come in contact with the outer

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

periphery of the bangle and pushes the open end so that the molten open ends
come in contact with each other resulting a fine and strong joint.

12. PROCESS FLOW CHART

Production of bangle spiral from silica sand

Splitting the bangle spiral to individual

Bangle

Sorting

Straightening

Joining

Oil Filling & Packing

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

13. Academic Institution in Area:

Sr. Name of Institution Courses offered

No.
Guru Nanak Dev Engineering College Ludhiana Diploma and B.Tech in
Mechanical/Civil/Computer
1.
Science/ Electronics/ Electrical
Engineering
CT University Ludhiana Diploma,B.tech in
Mechanical/Civil/Computer
2.
Science/ Electronics/ Electrical
Engineering.
3. PCTE Group Of Institutes Ludhiana BBA,MBA,BCA,BSC,B.Com
Ludhiana Collage of Engineering Ludhiana B.tech in
Mechanical/Civil/Computer
4.
Science/ Electronics/ Electrical
Engineering.
Bhutta College of Engineering and Technology B.tech in Mechanical/Computer
5. Science/ Electronics/ Electrical
Engineering.
Punjab Agricultural University B.tech in Agriculture Engg/bio-
Technology/Food Technology/ BSc
6.
in Agriculture/horticulture/bio
chemistry/Microbiology.
Guru Angad Dev Veterinary Animal Sciences University B.tech in Dairy technology/Bio
7. Ludhiana. Technology,M.Tech in Dairy
chemistry and Dairy Microbiology.
Gulzar Group of institutes. Diploma,B.tech in
Mechanical/Civil/Computer
8.
Science/ Electronics/ Electrical
Engineering.
Govt. Industrial Training Institute Ludhiana ITI in
9. Carpenter/Draftsman/Electrician
Machinist/ Mechanic
Research and Development Centre for Bicycle and Diploma in
10. Sewing Machine. Mechanical/Automobile/Computer
science and Technology.

14. Centre of Excellence is suitable at CTR, Ludhiana

Suitability for:

Additional ( proposed for

S.No Particulars Details (Existing)
CoE)
A Physical infrastructure: CAD/CAM Lab , Machine and R&D Lab Facility
Welding Workshop/Machining

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

Workshop/Automation Lab.
Availability of Land for No additional land required
B 500Sq feet.
CoE
Availability of No additional Shed is
Available
building/Shed for CoE required.
C
Availability of hostel Available with 300 students No additional Hostel
facility for CoE capacity Required.
Human Resources
Core qualified technical 02
02
B staff for CoE
Operating staff 02
Trainers 02 01
Capability for providing Flame control and glass
Tool design, machine Design,
high quality technical Technology.
C Automation 4.0, CAD/CAM and
training in area of
CNC.
excellence
Association with Industry MoUs may be signed with
and Academia( number CDGI Firozabad to be
of MoUs /Agreements 05 nos. of MoUs with Academic associated as professional
D
with Industry, Academic institutions of the area expert.
Institutions, Research
bodies etc)
Accreditation/
F NSQF
Recognition of courses
Beneficiaries will be Rural
Industrialists of Ludhiana
and entrepreneurs who
G Targeted beneficiaries Yet not available.
wants to setup bangle
manufacturing facility in
Ludhiana.
The main focus area of the Selling of Bangle
centre is technical training in the straightening and joining
Identified focus areas for
H field of manufacturing for machine and Technology
CoE
students and unemployed youth transfer to Bangle
in the catchment area. manufacturers.
Promoting Techniques of
Glass Technology
Manufacturing of Bangle
Straightening and Joining
I Envisaged activities NIL
Machine
Educating and Technology
transfer to Rural
Manufacturers

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

CAPEX & OPEX

Capital Expenditure (CAPEX):

Sr. No. Expenditure head Cost

1 Renovation and setup of Research and 8.0 lacs
Development Lab facilities
Total 8.0 lacs

Operational Expenditure (OPEX):

Sr. No. Expenditure head Cost Cost Cost Cost

(1st Year) (2nd Year) (3rd Year) (4th Year)
1 Inputs, Raw materials and equipments for 8.0 Lacs 15 15 15
sorting machine
2 Inputs, Raw Materials and equipments for 10.0 Lacs 18 18 18
Straightening Machine
3 Inputs, Raw Materials and equipments for 14.0 Lacs 22 22 22
Joining Machine
4 Energy Cost 3 lacs 4 4 4
6 Professional expert fees 3.0 lacs 6 6 6
7 Stationary, publicity, Travel, telephone, 12 Lacs 10 10 10
transport, hospitality and other
overheads.
Total 50 75 75 75
Salary and manpower requirement

Sr. No. Designation No. of post Salary (month) Annual 4 years

1. Electrical Engineer 1 0.5 Lac 6.0 Lac 24.0 Lac
2. Design Engineer 1 0.5 Lac 6.0 Lac 24.0 Lac
3. Technician 1 0.2 Lac 2.4 Lac 9.6 Lac
4. Operator 1 0.2 Lac 2.4 Lac 9.6 Lac
Total 67.2 lacs

Total Project Cost for 04 Years: CAPEX + OPEX = 8.0 + 275.0 =284 lacs

Expected Outcomes:

Revenue model:

1. Technology Transfer and Royalty

Year Number of MSME Units Estimated Revenue (in Lakh)

Assisted
Year 1 01 2.5 Lacs
Year 2 03 7.5 Lacs
Year 3 05 12.5 Lacs
Year 4 07 17.5 Lacs

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 Central Tool Room Ludhiana
Ministry of Micro, Small and Medium Enterprise, Govt. of India Society
A-5, Phase-5, Focal Point Ludhiana 141010

Total 40 Lacs

Total revenue from Technology transfer and Royalty in 4 years: 40 Lacs

2. Selling of Machines

Year Machine Description Number of Machines Revenue Earned

01 Bangle Straightening and 01 25 Lacs
Joining Machine
02 Bangle Straightening and 05 125 Lacs
Joining Machine
03 Bangle Straightening and 05 125 Lacs
Joining Machine
04 Bangle Straightening and 05 125 Lacs
Joining Machine
Total Revenue Earned in 4 years 450 Lacs

Total Revenue Earned in 4 Years: 490 Lacs

Net Profit = Total Revenue – Total Expenditure = 490 – 284 = 207 Lacs

Internal Rate of Return: -

Year Capex (in Lacs) Opex (in Lacs) Revenue (in Lacs) Net Cash Flow (in Lacs)
st
1 Year 146.5 92.55 80.5 -158.55
2nd Year 0 119.85 201.5 81.65
3rd Year 0 120.15 221.5 101.35
4th Year 0 121.05 250.5 129.45

Net IRR of 4 Years = 0.915%

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