ceramic industry and research in india—problems and prospects

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This article was downloaded by: [Kungliga Tekniska Hogskola] On: 07 October 2014, At: 19:38 Publisher: Taylor & Francis Informa Ltd Registered in England and Wales Registered Number: 1072954 Registered office: Mortimer House, 37-41 Mortimer Street, London W1T 3JH, UK Transactions of the Indian Ceramic Society Publication details, including instructions for authors and subscription information: http://www.tandfonline.com/loi/tcer20 Ceramic Industry and Research in India—Problems and Prospects N. R. Sircar Published online: 04 Mar 2014. To cite this article: N. R. Sircar (1998) Ceramic Industry and Research in India—Problems and Prospects, Transactions of the Indian Ceramic Society, 57:1, 18-25, DOI: 10.1080/0371750X.1998.10804822 To link to this article: http://dx.doi.org/10.1080/0371750X.1998.10804822 PLEASE SCROLL DOWN FOR ARTICLE Taylor & Francis makes every effort to ensure the accuracy of all the information (the “Content”) contained in the publications on our platform. However, Taylor & Francis, our agents, and our licensors make no representations or warranties whatsoever as to the accuracy, completeness, or suitability for any purpose of the Content. Any opinions and views expressed in this publication are the opinions and views of the authors, and are not the views of or endorsed by Taylor & Francis. The accuracy of the Content should not be relied upon and should be independently verified with primary sources of information. Taylor and Francis shall not be liable for any losses, actions, claims, proceedings, demands, costs, expenses, damages, and other liabilities whatsoever or howsoever caused arising directly or indirectly in connection with, in relation to or arising out of the use of the Content. This article may be used for research, teaching, and private study purposes. Any substantial or systematic reproduction, redistribution, reselling, loan, sub-licensing, systematic supply, or distribution in any form to anyone is expressly forbidden. Terms & Conditions of access and use can be found at http:// www.tandfonline.com/page/terms-and-conditions

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Page 1: Ceramic Industry and Research in India—Problems and Prospects

This article was downloaded by: [Kungliga Tekniska Hogskola]On: 07 October 2014, At: 19:38Publisher: Taylor & FrancisInforma Ltd Registered in England and Wales Registered Number: 1072954 Registered office: MortimerHouse, 37-41 Mortimer Street, London W1T 3JH, UK

Transactions of the Indian Ceramic SocietyPublication details, including instructions for authors and subscription information:http://www.tandfonline.com/loi/tcer20

Ceramic Industry and Research in India—Problemsand ProspectsN. R. SircarPublished online: 04 Mar 2014.

To cite this article: N. R. Sircar (1998) Ceramic Industry and Research in India—Problems and Prospects, Transactionsof the Indian Ceramic Society, 57:1, 18-25, DOI: 10.1080/0371750X.1998.10804822

To link to this article: http://dx.doi.org/10.1080/0371750X.1998.10804822

PLEASE SCROLL DOWN FOR ARTICLE

Taylor & Francis makes every effort to ensure the accuracy of all the information (the “Content”)contained in the publications on our platform. However, Taylor & Francis, our agents, and our licensorsmake no representations or warranties whatsoever as to the accuracy, completeness, or suitabilityfor any purpose of the Content. Any opinions and views expressed in this publication are the opinionsand views of the authors, and are not the views of or endorsed by Taylor & Francis. The accuracy ofthe Content should not be relied upon and should be independently verified with primary sources ofinformation. Taylor and Francis shall not be liable for any losses, actions, claims, proceedings, demands,costs, expenses, damages, and other liabilities whatsoever or howsoever caused arising directly orindirectly in connection with, in relation to or arising out of the use of the Content.

This article may be used for research, teaching, and private study purposes. Any substantial orsystematic reproduction, redistribution, reselling, loan, sub-licensing, systematic supply, or distribution inany form to anyone is expressly forbidden. Terms & Conditions of access and use can be found at http://www.tandfonline.com/page/terms-and-conditions

Page 2: Ceramic Industry and Research in India—Problems and Prospects

Ceramic Industry and Research in India - Problems and Prospects* HoN'BLE CHIEF GuEsT/CHAIRMAN, ORGANISING COMMITTEE/

DISTINGUISHED GUESTS/INVITEES/FELLOW DELEGATES/LADIES AND GENTLEMEN:

I have the privilege of according a cordial welcome to all of you who have assembled here from far and ncar1 from India and abroad, to participate in the 61 st Annual Session of our Society. My sincere thanks arc due to Dr. K. N. Maiti, Chairman and Mr. B. N. Das, Secretary, Organising Com­mittee as well as to their dedicated team of workers who had toiled hard for the last several weeks to make the Annual Session a resounding success. I hope the two-day delibera­tions in this forum by various cross-sections of people, viz. entrepreneurs, scientists and technologists, representatives from educational institutions, Government agencies, equip­ment manufacturers and raw material!) suppliers in the tield of ceramics will be beneficial to the participants through exposure to innovations and cross-fertilisation of ideas. Apart from this, the Session will provide an opportunity to renew old bonds of friendship and forge new ones.

I would like to make a brief presentation of the profile of the present status as well as the problems and prospects ofthe ceramic industry in India.

Friends, you arc aware that the continued growth dur­ing the last several years has achieved success in certain areas. India is now the lOth largest steel making and the 4th largest cement producing country in the world with pro­duction of international standard.

The general scenario of the economic and industrial development in the country in the immediate past is. how­ever, not encouraging. The growth in industrial and manu­facturing sectors in the first quarter of the current year (April-June 1997) were 5.2% and 4.8% respectively against 12o/r and 15.4% last year. Export in 1996-97 registered only 4% growth against 21 'k during I ()95-96. But the slump in growth of demand and export is a global phenomenon. It may not be proper to term it as a recession at this stage. In 1996, world exports growth was only 4c;,. against 19.5o/c in 1995. The slowdown in Indian economy can be traced to various factors like high cost of capital, power shortage. increasing fuel cost, lack of adequate in­frastructure, procedural complexities resulting in delay, devaluation of currencies in various competing countries, political instability leading to reduced Foreign Direct In­vestment (FDI) etc. The Government has already taken several measures like lowering interest rates, reducing taxes on certain products etc, but more effective steps are necessary to provide a boost to the economy.

The ceramic industry too had to suffer a slowdown in

*Presidential Address delivered by Dr. N. R. Sircar at the 61st Annual Session of lnCcrS held at Ahmedabad during December 19 and 20, 1997.

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certain sectors. I do not play the Cassandra foretelling gloomy future ahead. In fact, I would like to call it a partial solar eclipse, temporary in nature, out of which the bright sun of progress and economic growth will emerge. Besides, there are silver linings also. Flow of modern foreign tech-nology and equipment has improved the quality of several ceramic products in India leading to a large number of firms being awarded IS0-9000 group certification. An Indian firn1 has set up a modern refrac­tory plant in China.

Dr. N. R. Sircar delivering the Presidential address

The main problem is to increase productivity and reduce cost to ensure a level playing field for the Indian exporters. Through suitable blending of technology, upgrading of raw materials, utilisation of trained manpower and of course with Government policy support, it is possible to bring down the cost substantially. An instance is provided by the Italian tile industry. It is reported that cost reduction in raw materials for glazes resulted in savings of more than 70% in 1995 over 1975 through improved application technique, minimising glaze losses. A price decrease of 33% has been achieved by the Italian tile industry in the last 18 years during whichemployment of personnel was reduced by 10%, wages increased by 72% and production rose by 216%.

Present Status oflndian Ceramic Industry The performance of tfte ceramic industry in India is

quite impressive in most of the sectors. Introduction of modern foreign technology and equipment has vastly improved the quality, productivity and design variety and has given a competitive edge for Indian products in global market. Fast firing and single firing techniques have reduced the firing time drastically and now a days cycle time of forty or even thirty minutes for certain products has been achieved. This has resulted in reduction of fossil fuel consumption and consequent decrease in environmental pollution apart from other economic advantages.

The recent reduction of tax from 55% to 30% has provided a growth impetus for the industry. However, the industry expects a further lowering of tax to 15% or so.

Because of the high standard of Indian sanitaryware and tableware products and the high labour cost in deve­loped countries, there is immense scope for the foreign traders to source their requirements from India. Indian

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exporters may also profitably build up ties with foreign traders having wide distribution network for attaining ex­port augmentation.

The Government of India has increased the Ninth Plan size to Rs.374,000 crore, a sizeble part of which will be allotted to the building sector, providing an impetus to growth of the related ceramic sectors.

The ceramic industry sector has recorded an impressive balance of payment in foreign trade. Against a total import of ceramicware including insulators but excluding refrac­tories amounting to about Rs.31 crore, export reached Rs.l91 crore in 1996-97.

Glazed Tiles The glazed tile industry, reinforced by advanced for­

eign technology and equipment, showed spectacular progress having doubled the capacity in four years and attaining export growth of more than six times in the last six years. But the demand growth has been only 50%. There are 27 major producers and about I 00 others in the small scale sector located mainly in Gujarat, Rajasthan and Maharashtra with a few more units scattered in other States. This is a Rs.l 000-crore industry out of which the contribu­tion of small scale sector is Rs.200 crore. The total turnover is $300m which is only about 1.3% of the world turnover of $23.000 m. The present capacity is more than 0.57 million tonnes and with a few more tile units coming up and capacity expansion of a few others, the capacity is on the way to go up substantially. But sluggish demand may reduce the growth rate for some period due to a slowdown in the building industry. This sector showed a growth rate of 19% over the previous year.

Sanitary ware

15 units in the organised sector with an installed capac­ity of 0.11 million tpa produced about 0.08 million tonnes in 1996-97. Production in the small and medium scale sectors was about 0.03 million tonnes during the same period. Export is expected to reach about Rs.40 million. Growth rate was about I 0%. The total sanitary ware. including both organised and unorganised sectors. is estimated at about Rs.500 crore which is expected to be doubled by 2000 A.D.

Tableware The II units in the organised sector with installed capa­

city of about 0.04 million tpa, produced about 0.017 million tonnes of tableware consisting mainly of bone china. The units in the small scale sector produced about 0.0 I million tonnes. Growth rate was about 10%. Adoption of fast firing technique with roller hearth kilns contributed substantially towards quality improvement and cost reduction.

Insulators

Export of insulators has recorded a sharp rise of about 36% from Rs.66 crores in 1995-96 to an estimated

VOL. 57 ( 1) JANUARY - FEBRUARY 1998

Rs.90 crores in 1996-97. But the industry needs protection against threat from polymer insulators.

Refractories

About 80 units in the organised sector produced about 0. 77 million tonnes of refractories in 1996-97, major categories being high alumina, basic and fireclay refracto­ries. Export amounted to an estimated Rs.50 crore while import was to the tune of Rs.114 crore in 1996-97. The industry can meet the indigenous demand for conventional type of refractories, but a sizeable amount of high perform­ance refractories capable of withstanding savage tempera­ture and adverse furnace environments had to be imported although production of some of these types also has been set up and are also being exported.

About 75% of refractories are utilized by the iron and steel industry, 11% by the cement industry and the rest by other industries. India is now the I Oth largest steel pro­ducer in the world with present production of 20.4 million tpa which is estimated to increase to 29.2 mtpa in 2000 A.D. and 57 mtpa in 2012 with a growth rate of about 30% per year. The present steel export of 2.5 mtpa has been targetted to rise to 6.0 mtpa by 2000 A.D. The other indus­tries consuming refractories have also ambitious plans for growth. On the other hand, specific consumption for steel making is expected to come down from the present 27 kg to 18 kg/tonne of steel by 2000 A.D. For other industries also the specific consumption is expected to be substan­tially decreased.

There will, thus, be a changed pattern of refractory usage with increased demand on mag-carbon, chrome­alumina, dolomite, aluminium-carbon and Zr02-C and Zr02 refractories, continuous casting refractories like shrouds, monoblocks, slide gate refractories; silica bricks for coke ovens; ultra-low and no-cement castables etc. Demand for sialon-bonded silicon carbide, ceramic fibres, refractory cement and mortars for repairing of furnaces will also increase. For high performance refractories of consistent quality, indigenous production on commercial scale are be set up for consistent quality synthetic raw materials like tabular and fused alumina, high purity sintered magnesia. fused magnesia, mag-chrome co-sinter, colloidal and fumed silica, mullite aggregates, high alumina cement, etc.

It is heartening to note that the plant for making sea­water magnesia in India and the refractory plant set up in China for making mag-carbon refractories wholly owned by an Indian firm have both gone into production and that a number of production firms have been awarded the ISO 9000 group certification. Indigenous production of continu­ous casting refractories, so far imported, has also been set up.

Glass

Glass industry slided from its favourable balance of payment position in foreign trade due to a spurt in import.

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Table I : Export of Glass, Ceramic and Allied Products (Rs. in crores : 1 crore = 10 million)

Items 1992-93 1993-94 1994-95 1995-96 1996-97*

A. Glass and Glassware

Vacuum flasks and refills 28.20 26.83 30.14 35.88 32.80 Safety glass sheets 0.52 0.34 1.55 1.68 2.30

Sheet glass unworked 4.21 7.97 8.90 14.41 10.00

Figured and wired glass 2.79 2.29 2.56 6.68 3.60 Float glass 1.77 9.45 46.09 122.63 62.50

Glass mirrors 0.35 0.70 2.02 5.77 6.60

Glass vials (for injectibles) 1.87 2.61 4.35 4.66 6.70

Bottles, phials, etc 26.00 37.01 59.80 52.04 42.00

Glass bangles 0.86 1.20 0.14 1.43 1.80

Glass beads and false pearls 8.15 13.98 11.69 15.68 12.10

Optical lenses 7.29 9.02 10.03 11.80 15.60

Clinical thermometers '1.62· 7.24 6.54 6.57 3.80

Scientific g1asswares 3.81 1.30 3.15 4.14 8.20

Glass table/ kitchenware 1.77 2.12 4.53 5.20 6.10

Other glass and glassware 27.33 38.36 27.41 27.81 39.40

TOTAL: 122.54 160.42 218.90 316.38 253.50

B. Ceramics including Refractories

Sanitaryware 15.81 26.29 33.02 44.24 37.10

Insulators 28.52 42.52 38.13 65.72 90.00

Glazed ceramic tiles 22.61 27.47 36.85 32.64 33.50

Potteryware 5.86 5.42 7.03 15.71 15.00

Roofing tiles 1.01 2.30 1.84 1.23 2.00

Other ceramic products 9.48 6.19 12.38 5.96 13.70

Refractories & refractory construction materials 16.11 23.54 29.00 37.04 50.00

TOTAL: 99.40 133.73 158.25 202.54 241.30

c. Cements, Clinkers, etc

Cement 98.28 168.99 211.81 195.34 240.00

Clinkers 33.87 117.25 168.96 105.12 103.00

Asbestos cement products 2.15 9.59 8.51 12.99 11.10

TOTAL: 134.30 295.83 389.28 313.45 354.10

*Provisional Source . CAPEXIL Annual Report 1996-97

With the introduction of indigenous production of float glass and TV tubes, the import would come down signifi­cantly. Before 1992, there was no float glass production unit in the country. In 1996-97, this has become the highest export item in !J'lass category, reaching Rs.62.5 crores. Clear float glass and tinted heat absorbing float glass have attained international standard.

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Advanced Ceramics 75% of advanced ceramics market is occupied by elec­

tronic ceramics followed by high performance ceramic coatings constituting about 10%. Ceramic cutting tools also occupy a significant position. India has entered into this field and has initiated production, though on a moder­ate scale, in ferrites, cutting tools and structural ceramics,

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A.

B.

Table II : Import of Glass, Ceramic and Allied Products

(Rs. in lakh : I 0 lakh = I million)

Items 1993-94

Glass & Glassware

Cullet and other waste glass 2.7

Glass balls, rods tubes, unworked 692.8

Cast and rolled in sheets, wired glass 73.7

Drawn and blown glass in sheets 92.6

Float glass and surface ground/ polished glass 929.6

Glass fitted with other materials 5.6

Safety glass (toughened/laminated) 325.0

Glass mirrors 96.9

Multiple walled insulating glass 40.9

Container glassware 225.0

Glass envelopes (cathode ray tubes, bulbs, tubes etc) 6295.7

Glass inners for vacuum flasks 6.3

Glass table/kitchenware 44.7

Signalling glass 150.1

Clock/watch glasses, spectacles (including

ophthalmic and optical glass) 1295.4

Pressed/moulded glass, construction glass 27.9

Lab/pharmaceutical glassware 180.8

Beads, jewellery glass, bangles 624.1

Glass fibre/wool, articles made thereof 2750.7

Electrical insulators of glass 30.8

Electrical insulating fittings, wholly of glass 71.5

Others 572.8

TOTAL: 14535.6

Ceramics

(a) Insulators

Porcelain discs & strings< 6.6 KV 20.8

Porcelain discs & strings 6.6 KV and above 1.5

Porcelain solid core insulators (HT) -

Porcelain post/pin insulators< 6.6 KV 4.8

Porcelain post/pin insulators> 6.6 KV -

Porcelain post/pin insul<itors above 132 KV 6.7

Parcel a in post/pin insulators 11-66 KV -

Porcelain pin insulators> 66 KV -Telegraph and telephone insulators of porcelain

(shackles, reels, cartons, cleats) (L T) 99.7

Porcelain bushings< 6.6 KV 12.2

Porcelain bushings> 6.6 KV -

Other porcelain fittings for electrical equipment 164.0

TOTAL: 309.7

VOL. 57 ( 1) JANUARY- FEBRUARY 1998

1994-95 1996-97

13.85 33.32

1302.49 1739.70

148.83 182.27

138.18 157.18

2663.25 2680.87

42.33 33.50

406.21 413.23

146.22 181.88

142.65 3.84

333.48 562.68

9973.70 11163.58

7.82 0.57

162.36 212.61

272.03 292.04

2046.60 2892.93

575.31 347.00

203.80 314.00

683.45 864.86

3256.02 4320.53

14.49 108.76

31.98 106.57

807.02 838.14

23372.07 27450.06

34.24 64.82

- 0.62

- 38.09

3.07 0.38

- 6.09

- -

2.71 -

2.37 -

35.88 120.90

8.54 42.54

- 12.06

116.63 227.90

203.44 513.40

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Table II (contd)

Items 1993-94 1994-95 1996-97

B. Ceramics (contd)

(b) Ceramic (pottery)

Ceramic building bricks, blocks, pipes, conduits etc 27.9 24.47 69.06

Ceramic tiles, mosaic etc 14.9 30.84 84.07

Ceramic laboratoryware 347.0 745.37 771.99

Ceramic tableware/kitchenware 30.2 119.20 135.55

Other ceramic articles 1005.0 1237.11 1513.80

TOTAL: 1425.0 2156.99 2574.47

c. Refractories

Insulating bricks and blocks (fossil meal) 110.1 394.99 311.75

Refractory bricks, blocks :

Magnesite bricks and shapes b/s 335.0 359.94 558.36

Chrome magnesite b/s 12.2 - 10.27

Mag-carbon b/s - 105.11 310.40

Magnesite chrome b/s 33.6 0.94 14.87

Direct bonded basic b/s 166.0 263.47 563.61

Silica b/s 174.1 36.99 45.79

High alumina b/s 4.8 93.20 55.59

Alumina carbon b/s - 17.94 15.28

Silicon carbide b/s 4.3 27.94

Mullite b/s 8.9 54.11 63.94

Fireclay b/s 36.0 158.18 473.20

Graphite carbon b/s - 58.79 352.14

Clay graphite stopper heads - 151.50 10.36

Other refractory bricks, blocks, tiles etc 1648.3 3908.61 4492.75

Other refractory ceramic articles (crucibles, retorts etc):

Mag-carbon b/s 84.0 26.65 79.14

Silicon carbide crucibles 32.4 25.91 125.43

Zircon, zircon mullite refractories 62.1 106.55 271.33

Ceramic fibres 2.5 23.25 17.83

Monolithic/castables 46.5 24.39 0.92

Others 3692.5 3581.91 3588.68

TOTAL: 6453.3 9420.37 11361.64

Source : DGCIS, Govt of India

IC substrates, optical and laser glasses of various types, pressure sensors, non-oxide refractories like zirconia, sili­con carbide, silicon nitride etc. This is an emerging field but the advanced ceramics industry is still in the nascent state with a limited demand.

With availability of modern advanced technology backed by scientific, technical, engineering, R & D and managerial skill available in the country, the progress of ceramic industry in India is reasonably bright.

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Impact of Globalisation Globalisation has acted as a shock therapy to the long

sheltered Indian economy and industry providing both op­portunities and threats. Whether we like it or not, globalisation has come to stay and the days of insular and command economy may well be considered a thing of the past. But globalisation should not be absolutely free to operate unabatedly in all sectors, at least during the first decade, particularly in case of common consumer goods

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Table III : Production of Glass, Ceramics and Refractories

Installed Production Items capacity in

1995-96 1991-92 1992-93 I 993-94 1994-95 1995-96 (estimated)

A. Glass & Glassware*

Containerware ('000 MT) 725.0 650.0 715.0 716.6 720.0 739.0

Sheet glass (million m2) 65.0 42.0 44.1 46.0 50.0 50.0

Float glass (million m2) 65.0 - - 20.0 25.0 50.0

Fibre glass ('000 MT) 10.0 4.6 8.0 8.5 9.4 10.0

Glass wool ('000 MT) 6.0 1.5 2.5 2.5 2.0 2.0

Lab glassware ('000 MT) 27.2 13.0 14.0 16.9 17.8 19.0 (including neutral glass tubes

B. Ceramics*

Glazed tiles ('000 MD 565.5 272.0 300.0 350.0 402.5 500.0

Tableware ( '000 MT) 38.5 16.5 15.7 15.0 17.0 17.0

Sanitaryware ('000 MT) IOI.I 70.0 66.5 73.2 76.0 78.0

H. T. insulators ('000 MT) 73.2 50.0 50.0 46.0 50.0 na

c. Refractories ('000 MT)**

Fireclay 600.0 234.3 214.6 222.9 265.8 186.2

High alumina 300.0 138.7 152.4 137.0 183.0 246.6

Silica 60.0 19.1 26.9 22.3 27.6 38.2

Basic 285.0 211.6 190.3 176.5 207.3 208.2

Special products 42.0 9.5 I 1.4 11.8 12.3 19.7 (electrocast (AZS), slide gate, continuous casting, ceramic fibre, Zr/Zr-mullite)

Others 125.0 73.5 71.3 79.6 81.2 67.4

Sources: *Ministry of Industry, GO! and Economic Times Data Book (I 995); **IRMA

for which indigenous capabilities exist.

Globalisation has three main imperatives : Cost reduc­tion and quality improvement supported by improvement in service sectors and infrastructure development. These arc essential for achieving competitiveness in global markets. Added to these are the essentiality of improving the R & D base, upgradation of indigenous technology and inflow of FDI along with modern technologies and equipment. The ceramic industry has benefited much taking advantage of these modernisation programmes. A number of ceramic units have acquired ISO 9002 Certification and have hiked their exports in the face of fierce global competition.

The adverse effect has been manifest in enhanced import bills in respect of certain glass and ceramic prod­ucts, apart from the necessary production and testing equipment. For instance, the import of refractories in­creased by about 45% from Rs.65 crore in 1993-94 to Rs.94 crore in 1994-95 and by about 75% (over I 993-94) to an estimated Rs. I I 4 crore in 1996-97. During the same

VOL. 57 ( 1) JANUARY- FEBRUARY 1998

period (1993-94 to I 996-97), however, export of refracto­ries more than doubled from Rs.24 crore to an estimated Rs.50 crore. In terms of percentage, it may sound impres­sive but in absolute amount not so bright in view of the impact of inflation and devaluation of currency. Total im­port of glass, ceramic and refractory items increased from about Rs.227 crore to Rs.420 crore while total export rose from about Rs.200 to Rs.500 crore during I 993-94 to 1996-97. Tables I, II & III will reflect a clearer picture of the trend in the industry.

Research and Development

Globalisation and FDI alone cannot usher in economic and industrial regeneration of the country - they can at best be catalysing factors. The new technologies should be amenable to indigenous raw materials and environments. The role of R & D has gained added importance to attain the synthesis and to surge forward towards newer develop­ments. The Central Glass & Ceramic Research Institute is

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the pioneering R & D institution devoted to glass, ceramics and allied materials along with testing and evaluation. But the infrastructural facilities and equipment inventory have to be substantially augmented and modernised to enable it to face the challenges. This may also help towards getting foreign sponsorships regarding testing and evaluation, developing new materials as well as undertaking basic research projects since the cost will be reduced by an order of magnitude.

There are quite a few other R & D Centres, both in private and public sectors, carrying on commendable work in upgrading technologies, making innovations leading to improvements in quality, cost-effectiveness and reliability.

Pollution

The ceramic industry suffers from two kinds of pollu­tion hazards : inclusion of hazardous constituents like lead, cadmium in the composition and emission of noxious gases and particulate matters resulting from combustion of fossil fuels. There has been worldwide concern for reduc­ing the "Greenhouse Effects" resulting from unrestricted emission of C02, CFC (chlorofluorocarbon) etc in the atmosphere. The 1992 Rio Earth Summit recommendation to reduce the emission was not honoured by several highly developed countries. The mandatory cut by about 15%, likely to be imposed by the 1997 Kyoto Summit held earlier this month (December 3-10, 1997) is expected to trigger more energy efficient conversion of fossil fuel through application of new technology. Catalytic conver­sion of noxious gases through porous ceramics and ceramic membranes is expected to find a prominent place in not-too-distant future and setting up a new product market in ceramics.

The USA and some other developed countries have been hardening the regulations regarding pollution control through imposition of stringent limit for lead and cadmium content in glazed tableware. Indian manufacturers and exporters should keep a watch on these measures so that exports may not be affected as in the case of seafood and coloured textile industries. This is also essential for a competitive edge in export markets, particularly in view of the forecast that Asia will supply the bulk of traditional ceramics to the world in the early next century.

Ceramic technology as well as other production tech­nologies has reached a watershed. It must not only contrib­ute to economic growth but should also be 'clean' to ensure the ecological sustenance.

Electricity is the least pollution generating fuel but is scarce and costly. Natural gas is a moderately clean fuel but its availability is highly restricted at present. Natural gas from Bombay High has provided a boost to ceramic industry in Western Sector. Extension of HBJ pipeline to Khurja and Haridwar will prove to be a boon in those areas. Govt is negotiating deals for bringing supply of natural gas from Bangladesh, Tripura, Assam and Myanmar through

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Bangladesh to the Eastern region and from the Arab Emir­ates and other sources from the Middle East to the Western region by laying pipelines. If these ambitious projects ma­terialise, India will take a giant leap forward in economic growth including a spurt in ceramic industry, both qualita­tively and quantitatively.

Adoption of fast firing technology and modern kilns capable of oxidation of noxious gases will also contribute towards reduction of environmental pollution.

Ceramic Education The inadequacy of properly trained manpower, particu­

larly at middle management level, has been a decelerator in growth of ceramic industry. A ceramic technologist should be a multi-disciplinary person having in-depth knowledge in designing the layout of plants, selection of raw materials and equipment, forming, melting and firing techniques, physics and chemistry of ceramics, interface reactions etc in addition to preparation of budgets, handling labour relations and looking after mechanical, energy and pollution problems. The curricula, teaching methods and training facilities should take care of all these factors.

There are six Universities and Engineering Colleges offering Bachelor's and higher degrees in ceramic science and technology with one more proposed to be set up with foreign collaboration. The Indian Institute of Ceramics also confers Associateship (throu.~lt examination) which is recognised by the Govt of India as equivalent to first degree in ceramics. In additio•1, four liT's offer Bachelor's and higher degrees in Material Science with specialisation in ceramics. Moreover, nine Polytechnics and Technical Institutes offer Diploma in Ceramic Engineering and a few more are likely to come up in near future. About half a dozen centres offer training in ceramic art and pottery as well as in designing.

The main problem thus is modernisation of the curricu­lum and teaching methods in consonance with the rapid advances of ceramic science and technology as well as with the principles and operation of modern sophisticated tools of characterisation like XRF. XRD, SEM, TEM, ICP etc leading to increased understanding of structure-prop­erty relationship. It is heartening to note that the Govt is alive to the situation and is on the move to revise the curricula, but the process needs be accelerated.

Maintenance and expansion of high standards in teach­ing and R & D require increased resources but there has been a worldwide crunch in funding. It is interesting to study the "Dearing Report" published by Sir Ron Dearing last year on purposes, shape, structure, size and funding of higher education in general for UK students, but the broad­based report is relevant for other countries also. Charging of means-tested tution fees with provision for exemption for low-income families, provision of "Students Loan" repayable after their securing employment, creation of Industrial Partnership Development Fund with matching contribution from industry, provision of sponsorship and

TRANSACTIONS OF THE INDIAN CERAMIC SOCIETY

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Page 9: Ceramic Industry and Research in India—Problems and Prospects

vacation employment by the industry, staff development policies for existing faculties etc are some of the salient recommendations.

A ceramic engineer of tomorrow must be open minded and receptive to new ideas and experimentation. As Prof. J.

Alexander Chediak of Alfred University aptly put it, "An Edisonian approach should be considered in conjunction with Aristotelian methods".

The Expanding Frontiers of Ceramics

The revolution in materials science and technology en­compasses three cornerstones - metals, ceramics and polymers as well as the numerous composites formed by their various combinations. There are certain new ceramic materials and techniques which are in the horizons at present. But the world has been reduced to a global village and it will be not before long that they will be knocking at the threshold of the Indian ceramic industry to get adopted. I am tempted to quote some specific examples having future far-reaching effects on our industry, e.g. NZP (Sodium-Zirconium-Phosphate) ceramics- a new class of materials with low thermal expansion, high thermal shock resistance and other unique thermo-physical properties finding potential applications in furnace support structures and baffles, ceramic fibre composites, thermal spray coat­ings etc; Lanxide process for making super refractories with very high fracture toughness having potential applica-

VOL. 57 ( 1) JANUARY- FEBRUARY 1998

tions in fabricating gas turbine engine and missile compo­nents with higher fuel combustio1; temperature as well as in aerospace industry; Ormocers (organically modified ce­ramic oxides) and photochromic organic molecules trapped in sol-gel derived Ornwsils (organically modified silicates) in the form of bulk materials or thin films having practical potential applications for erasable optical memory, imaging filters and opti-:al switching; microwave firing; injection moulding of ceramic bodies; Chemically vapour deposited diamond coating for wear applications, optical testing of tiles, etc.

Acknowledgement I would take this opportunity to express my sincere

thanks to all of you for attending the Session and making it a success. I am grateful to the eminent Council Members, particularly to my predecessor Mr. H. L. Somany, the eminent industrialist in ceramic field, Dr. C. Ganguly, Vice-President (lnCerS) and Director, CG & CRI, Mr. Amit Kr De, Hony Secretary, Mr. D. R. Sen, Hony Treas­urer and Dr. H. S. Maiti, Hony Editor. My sincere appre­ciation goes to Mr. T. P. Bhattacharya for his able assist­ance in compiling the data and other relevant matters in preparing this address. Thanks are also due to Mr. A. K. Banerjee, Executive Secretary, Mr. T. Chakraborty, Sr. Executive and other members of the Secretariat Staff of the Society for their wholehearted support and cooperation.

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