BALL PEN REFILL MAKING |

SMALL SCALE MANUFACTURING

Muvsi Research Desk Last updated on: 18/05/2016
Ball pen refill making process is simple and can be initiated as a home
based manufacturing operation with moderate startup capital investment.
Ball pen is the essential writing instrument for students, for the
educational institution and in a type of office work. Wide and increasing
usage of ball pen and refills has made this product as the mass
consumable item. There is always a very good demand for quality ball pen
and refill. Nowadays use-and-throw pens are very popular among the
students. Any individual can start this manufacturing operation by having
simple machinery. Required raw material is also can be procured locally.

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Ball Pen Refill Making | Small Scale Manufacturing

BALL PEN REFILL MAKING |

SMALL SCALE MANUFACTURING
Muvsi Research Desk Last updated on: 18/05/2016

Ball pen refill making process is simple and can be initiated as a home
based manufacturing operation with moderate startup capital investment.
Ball pen is the essential writing instrument for students, for the
educational institution and in a type of office work. Wide and increasing
usage of ball pen and refills has made this product as the mass
consumable item. There is always a very good demand for quality ball pen
and refill. Nowadays use-and-throw pens are very popular among the
students. Any individual can start this manufacturing operation by having
simple machinery. Required raw material is also can be procured locally.
BALL PEN REFILL MAKING BUSINESS REGISTRATION

In starting ball pen refill making you will

need to register your business First. For a small scale unit, according to
your ownership pattern of the firm you can register as OPC or LLP or Pvt.
Ltd company. You will need to obtain Trade License for local Municipal
Authority and Vat Registration. Other statutory requirements are having
Pan Card and Current Bank Account. This type of manufacturing activity
doesn’t attract Pollution Control Board License.

FINANCE FOR BALL PEN REFILL MAKING BUSINESS

Ball pen and refill manufacturing in an assembling process are a micro
scale industry. You can arrange finance from your or known circle or you
can apply for a MUDRA Bank Loan. In any case, you will need to have a
project report with details of machinery cost, raw material cost and
working capital investment plan. The Proper financial analysis you must
have before applying for a loan or any type of finance from financial
institutions.

BALL PEN REFILL MAKING MACHINERY

In starting a ball pen refill making unit, 200 sqft onwards area is required.
Major Required machinery are

1. Punching machine
2. Ink filling machine
3. Nozzle fixing machine
4. Centrifuging machine
5. Hot stamping machine.
Ball pen refill making unit also can be established as fully automatic basis.
Technically upgraded fully automatic ball pen refill making machine is also
available in the market. According to your available finance and desired
output, you must choose the right machinery for the project.

BALL PEN REFILL MAKING RAW MATERIAL

The required raw materials are liquid ink, pipe and nozzle. All the raw
material can be procured from the local wholesale market or from the
manufacturer. You will also need to arrange packaging consumables such
as plastic wrappers and the cardboard box for outer packing.
BALL PEN REFILL MAKING PROCESS
Ball pen refill making process is simple. It only needs following steps:

1. Filling the pipe with predetermined ink quantity.

2. Fixing the nozzle
3. Embossing your brand name
4. Packing

MARKET SURVEY CUM DETAILED TECHNO

ECONOMIC FEASIBILITY REPORT covers

• Introduction
• Properties
• BIS (Bureau of Indian Standard) Specifications & Requirements
• Uses & Applications
• Present Indian Market Position
• Expected Future Demand
• Export & Import Statistics Data
• Names and Addresses of Existing Units (Present Manufactures)
• List of Plant & Machineries
• Miscellaneous Items and Accessories
• Instruments, Laboratory Equipments and Accessories
• Electrification, Electric Load and Water
• Maintenance, Suppliers/Manufacturers of Plant and Machineries
• Process of Manufacture with formulae if applicable
• Flow Sheet Diagram
• List of Raw Materials
• Availability of Raw Materials
• Requirement of Staff & Labour
• Personnel Management
• Skilled & Unskilled Labour
• Requirement of Land Area
• Built up Area
• Plant Layout.

along with financial details as under:

Summary of Capital Cost of Project

Land & Side Development Exp.
Buildings
Plant & Machineries
Misc. Fixed Assets
Technical Know how Fees & Exp.
Preliminary Expenses
Pre-operative Expenses
Provision for Contingencies
below mentioned financial statements (Annexure) will be for 5 to 10 Years
Annexure :: Cost of Project and Means of Finance
Annexure :: Output, Profitability and Cash Flow Chart
Annexure :: Assessment of Working Capital requirements
Annexure :: Sources of Finance
Annexure :: Balance Sheets
Annexure :: Break-Even Analysis and profitability analysis.
 Annexure :: Quantitative Details-Output/Sales/Stocks
Annexure :: Sales Realisation
Annexure :: Raw Material Cost
Annexure :: Other Raw Material Cost
Annexure :: Packing Material Cost
Annexure :: Consumables, Store etc.,
Annexure :: Employees Expenses
Annexure :: Fuel Expenses
Annexure :: Power/Electricity Expenses
Annexure :: Repairs & Maintenance Exp.
Annexure :: Other Mfg. Expenses
Annexure :: Administration Expenses
Annexure :: Selling Expenses
Annexure :: Depreciation Charges - Profitability
Annexure :: Depreciation Charges
Annexure :: Interest and Repayment - Term Loans
Annexure :: Tax on Profit
Annexure :: Assumptions for Profitability workings
Annexure :: Assessment of Working Capital

Engineers India Research Institute (EIRI) is a renowned name in the industrial world for offering
technical and financial consultancy services.

Refill is most useful gadget for our daily use. “Use and Throw” ball pen is very popular every
where like school ,college, office etc. Use and Throw pen is highly demand able thing in market
in view of price and uses. Here is tips for establish a small scale industry for Ball Pen Refill
making plant.
There are many types of Ball pen refill machine is available in market. A model range of ball pen
refill making machine comes from Rs. 5,000 to 7,500. The much advance machine for ball pen
refill making is available from Rs. 8,000 to Rs. 12,000. The other important things to be used in
ball pen refill making as raw material are – Pipe – Rs. 85/- per Kg., Ink- Rs. 120 to Rs. 400,
Nozzle – Rs. 24 to Rs. 135 per grues ( One Grues = 144 piece) , Plain rapper- Rs. 160 to Rs.
240 per thousand, Golden ribbon and Name Block. All materials are available at shop where you
buy plant machine. The training of refill making is very simple. You can learn all process of ball
pen refill making in only 7-8 days. The size of total plant is so small that all plant may come on a
6/6 table.
The product sells at grues base. It means that wholesalers buys the refills at grues base. There
are 12 dozens refills come in a grues. One grues (144 ) refill may be produced in 3-4 hrs. You
can earn Rs. 250-400 per day form a small size ball pen refill making plant.

A ballpoint pen is a writing instrument which features a tip that is

automatically refreshed with ink. It consists of a precisely formed
metal ball seated in a socket below a reservoir of ink. As the pen is
moved along a writing surface, ink is delivered. Even though
ballpoint pens were first patented in the late nineteenth century,
they only started to reach commercial significance in the early
1950s. Now, ballpoint pens dominate the writing instrument market,
selling over one hundred million pens each year worldwide.
History
While the idea of a ballpoint pen had been around for many years, it
took three different inventors and almost 60 years to develop this
modern writing instrument. The first patent for this invention was
issued on October 30, 1888, to a man named John J. Loud. His
ballpoint pen consisted of a tiny rotating ball bearing that was
constantly coated with ink by a reservoir above it. While this
invention worked, it was not well suited for paper because it leaked
and caused smearing. Two other inventors, Ladislas Biro and his
brother Georg, improved on Loud's invention and patented their own
version, which became the first commercially significant ballpoint
pen. These pens still leaked, but not as badly. They became popular
worldwide, reaching the height of sales in 1944. The next year
another inventor, Baron Marcel Bich, finally solved the leakage
problem and began manufacturing Bic pens in Paris. Over the years,
many improvements have been made in the technology and quality
of the various parts of the pen, such as the ink, the ball, the
reservoir, and the body.

Background
The ballpoint pen was developed as a solution to the problems
related to writing with a fountain pen. Fountain pens require the
user to constantly refresh the pen by dipping its tip in ink. This is
not necessary with a ballpoint pen because it is designed with its
own ink reservoir, which uses capillary action to keep the ink from
leaking out. At the tip of the pen is a freely rotating ball seated in a
socket. Only part of this ball is exposed; the rest of it is on the
inside of the pen and is constantly being bathed by ink from the
reservoir. Pressing the tip of the pen on the writing surface causes
the ball to roll. This rolling action then transfers ink from the inside
of the pen to the writing surface.
While different designs of ballpoint pens are available, many of the
components are the same. Common components include a ball, a
point, ink, an ink reservoir or cartridge, and an outer housing. Some
pens are topped with a cap to prevent it from leaking or having its
point damaged. Other pens use a retractable point system for the
same reason. Here a small spring is attached to the outside of the
ink reservoir, and when a button is pushed, the point is either
exposed or retracted. Still other varieties of ballpoint pens have
multiple ink cartridges, making it possible to write in different
colors using one pen. Other pens have refillable ink cartridges. One
type of pen has a pressurized cartridge that enables the user to
write underwater, over grease, and in space.

Raw Materials
A variety of raw materials are used for making the components of a
ballpoint pen, including metals, plastics, and other chemicals. When
ballpoint pens were first developed, an ordinary steel ball was used.
That ball has since been replaced by a textured tungsten carbide
ball. This material is superior because it is particularly resistant to
deforming. The ball is designed to be a perfect sphere that can
literally grip most any writing surface. Its surface is actually
composed of over 50,000 polished surfaces and pits. The pits are
connected by a series of channels that are continuous throughout
the entire sphere. This design allows the ink to be present on both
the surface and interior of the ball.
The points of most ballpoint pens are made out of brass, which is an
alloy of copper and zinc. This material is used because of its
strength, resistance to corrosion, appealing appearance, and ability
to be easily formed. Other parts, like the ink cartridge, the body, or
the spring can also be made with brass. Aluminum is also used in
some cases to make the pen body, and stainless steel can be used
to make pen components. Precious metals such as gold, silver, or
platinum are plated onto more expensive pens.
The ink can be specially made by the pen manufacturer. To be useful
in a ballpoint pen, the ink must be slightly thick, slow drying in the
reservoir, and free of particles. These characteristics ensure that
the ink continues to flow to the paper without clogging the ball.
When the ink is on the paper, rapid drying occurs via penetration
and some evaporation. In an ink formulation, various pigments and
dyes are used to provide the color. Other materials, such as
lubricants, surfactants, thickeners, and preservatives, are also
incorporated. These ingredients are typically dispersed in materials
such as oleic acid, castor oil, or a sulfonamide plasticizer.
A 1963 plastic and metal ballpoint pen commemorating the assassination of President
John F. Kennedy, Jr.

(From the collections of Henry Ford Museum & Greenfield Village.)

Until the advent of the computer, humans have scrambled to find

writing instruments to record story and song. The earliest scribbles
were made with a burnt stick in sand. By the fourth century B.C. , the
Sumerians used wedge-shaped reed pens to cut pictorial shapes
into clay tablets. Eygptians painted hieroglyphics with brushes
made from marsh reeds and the ancient Chinese wrote with brushes
of stiff hair. Ancient Greeks and Romans sharpened stiff reeds to a
point, resulting in chirography that was taut and precise.
The quill pen, made from goose or swan feathers, was favored by
writers for over 1,000 years. The soft quill was honed to a point,
split at the tip to permit ink to flow freely, and constantly
resharpened. A monumental improvement over the quill pen was
Joseph Gillott's invention of the steel pen nib in the late nineteenth
century, which required no sharpening and could be separated from
the pen body and changed as needed. Still, the writer constantly
dipped pen into ink, hoping to avoid drips.
Fountain pens store ink inside a reservoir within the pen, the nib
thus supplied with a constant stream of ink. Alonzo Cross featured a
"stylographic pen" with an ink-depositing needle point in the late
1860s, but blots and smears were still common. However, the
ballpoint pen virtually eradicated messes. Ballpoint pens
manufactured early in the century leaked, skipped, and dropped ink
until 1950, when a new ink was developed that made the ballpoint
reliable.
Nancy EV Bryk
Plastics have become an important raw material in ballpoint pen
manufacture. They have the advantage of being easily formed,
lightweight, corrosion resistant, and inexpensive. They are primarily
used to form the body of the pen, but are also used to make the ink
cartridge, the push button, the cap, and part of the tip. Different
kinds of plastics are used, based on their physical characteristics.
Thermosetting plastics, like phenolic resins, which remain
permanently hard after being formed and cooled, are typically used
in constructing the body, cap, and other
pieces. Thermoplastic materials remain flexible. These include
materials like high-density polyethylene (HDPE) and

vinyl resins, which can be used to make most of the pen components.

The Manufacturing
Process
Ballpoint pens are made to order in mass quantities. While each
manufacturer makes them slightly differently, the basic steps
include ink compounding, metal component formation, plastic
component molding, piece assembly, packaging, labeling, and
shipping. In advanced shops, pens can go from raw material to
finished product in less than five minutes.

Making the ink

 1 Large batches of ink are made in a designated area of the
manufacturing plant. Here workers, known as compounders, follow
formula instructions to make batches of ink. Raw materials are
poured into the batch tank and thoroughly mixed. Depending on the
formula, these batches can be heated and cooled as necessary to
help the raw materials combine more quickly. Some of the larger
quantity raw materials are pumped and metered directly into the
batch tank. These materials are added simply by pressing a button
on computerized controls. These controls also regulate the mixing
 speeds and the heating and cooling rates. Quality control checks are
made during different points of ink batching.

Stamping and forming

 2 While the ink is being made, the metal components of the pen are
being constructed. The tungsten carbide balls are typically supplied
by outside vendors. Other parts of the pen, such as the point and the
body, are made using various molds. First, bands of brass are
automatically inserted into stamping machines, which cut out
thousands of small discs. The brass discs are next softened and
poured into a compression chamber, which consists of a steel ram
and a spring-backed ejector plunger. The steel ram presses on the
metal, causing the plunger to retract and forcing the metal into a die
cast mold. This compresses the metal and forms the various pen
pieces. When the ram and plunger return to their original positions,
the excess metal is then scraped off and recycled. The die is then
opened, and the pen piece is ejected.
 3 The formed pieces are then cleaned and cut. They are immersed in
a bath to remove oils used in the molding process. After they emerge
from the bath, the parts are then cut to the dimensions of the
specific pen. The pen pieces are next polished by rotating brushes
and cleaned again to remove any residual oils. The ball can then be
inserted into the point cavity.

Molding the housing

 4 The plastic components of the pen are constructed simultaneously
with the
 other pen pieces. They can be produced by either extrusion or
injection molding. In each approach, the plastic is supplied as
granules or powder and is fed into a large hopper. The extrusion
process involves a large spiral screw, which forces the material
through a heated chamber, making it a thick, flowing mass. It is then
forced through a die, cooled, and cut. Pieces such as the pen body
and ink reservoir are made by this method.

 5 For pieces that have more complex shapes, like caps, ends, and
mechanical components, injection molding is used. In this process
the plastic is heated, converting it into a liquid that can then be
forcibly injected into a mold. After it cools, it solidifies and
maintains its shape after the die is opened.

Ink filling and assembly

 6 After the components are formed, assembly can take place.
Typically, the ballpoint is first attached to the ink reservoir. These
pieces are then conveyored to injectors, which fill the reservoir with
the appropriately colored ink. If a spring is going to be present, it is
then placed on the barrel of the reservoir.
Final assembly, packaging, and shipping
 7 The point and reservoir are then placed inside the main body of the
pen. At this stage, other components such as the cap and ends are
incorporated. Other finishing steps, such as adding coatings or
decorations or performing a final cleaning, are also done. The
finished pens are then packaged according to how they will be sold.
Single pens can be put into blister packages with cardboard
backings. Groups of pens are packed into bags or boxes. These sales
units are then put into boxes, stacked on pallets, and shipped to
distributors.

Quality Control
The quality of pen components is checked during all manufacturing
stages. Since thousands of parts are made each day, inspecting
each one is impossible. Consequently, line inspectors take random
samples of pen pieces at certain time intervals and check to ensure
that they meet set specifications for size, shape, and consistency.
The primary testing method is visual inspection, although more
rigorous measurements are also made. Various types of measuring
equipment are available. Length measurements are made with a
vernier caliper, a micrometer, or a microscope. Each of these differ
in accuracy and application. To test the condition of surface
coatings, an optical flat or surface gauge may be used.
Like the solid pieces of the pens, quality tests are also performed on
the liquid batches of ink. After all the ingredients are added to the
batch, a sample is taken to the Quality Control (QC) laboratory for
testing. Physical characteristics are checked to make sure the
batch adheres to the specifications outlined in the formula
instructions. The QC group runs tests such as pH determination,
viscosity checks, and appearance evaluations. If the batch is found
to be "out of spec," adjustments can be made. For instance, colors
can be adjusted by adding more dye.
In addition to these specific tests, line inspectors are also posted at
each phase of manufacture. They visually inspect the components
as they are made and check for things such as inadequately filled
ink reservoirs, deformed pens, and incorrectly assembled parts.
Random samples of the final product are also tested to ensure a
batch of pens writes correctly.
The Future
Ballpoint pen technology has improved greatly since the time of
Loud's first patented invention. Future research will focus on
developing new inks and better designed pens that are more
comfortable and longer lasting. Additionally, manufacturers will
strive to produce higher quality products at the lowest possible
cost. One trend that will continue will be the development of
materials and processes which use metals and plastics that have
undergone a minimum of processing from their normal state. This
should minimize waste, increase production speed, and reduce the
final cost of the pens.

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