In the last decade, the silica sand market has undergone a dynamic transformation due to technological advancements, increased demand in the glass, foundry, and solar industries, and the growing need for high-purity sand. As the industry shifts to low iron and high silica content materials, the domestic supply chain has been put under immense pressure, which was dominated by imports. Historically, the Indian market sourced silica sand from regions such as Allahabad and Rajasthan. But the quality offered was poor and it could not meet the stringent requirements of modern industrial applications. In the absence of high-grade local sources, manufacturers were burdened with the high cost of importation of quartz or sand from countries like Egypt.
N.K. Kabra addressed this challenge by repurposing waste silica sand. One of the pioneering figures in India’s silica sand industry, N.K. Kabra is the recipient of the prestigious Udyog Bharati Award 2021. His revolutionary work repurposing waste silica sand (previously discarded during china clay mining in Bhuj, Gujarat) has set the country’s industrial raw materials market on a new course. This sand was considered worthless till 2012 and dumped across mining regions. Although one person tried to supply this sand to glass industry, they could not succeed. Kabra's deep industry experience and commitment to research helped him understand its true value. It was used in glass, foundry, and silicate industries, and he showed how it could replace imported materials, save foreign exchange, and develop the regional economy.
Through his foresight, he turned waste into a nationally vital resource and made Bhuj the silica sand capital of India. Through relentless efforts, he built a thriving ecosystem on the discarded mineral residue.
Discovering Untapped Potential in Bhuj's Waste Sand
Kabra’s breakthrough was based on his previous experience in West Bengal where he noticed there was usable silica sand produced as a byproduct in china clay processing. When he moved to Gujarat, he noticed the same thing happen in Bhuj too, where 80 percent of the mined material was waste silica sand being dumped, which had high silica content.
Kabra analyzed what the industry ignored. Along with the team members Vivek Sarin and Nitesh Jain, he collected samples and sent them to reputed testing agencies in China and the U.S. for confirmation of their quality. It was a sand that had over 99 percent silica and iron content of around 120 ppm and therefore was perfect for high-end glass manufacturing including solar. He was the first to use Bhuj sand in an industrial sense, a substance that had never been thought of as an input. That was the start of a resource revolution.
Building Bhuj into a Production Hub
Large volumes of silica sand are produced in Bhuj thanks to Kabra’s in-depth knowledge of supply chain management. As Joint President and Business Head at HNG Float Glass Ltd. (now SISECAM), he had first-hand experience with sourcing and quality issues facing the glass industry. Encouraged by his visionary chairman C.K. Somany, He brought in Bhuj sand into their own manufacturing ecosystem. They started from the lab level and slowly scaled capacity from 5
percent to full. He had very limited infrastructure at Bhuj, so he arranged for the wet transport itself to their factory, dried and purified it, and validated its performance. He recognized the commercial promise of his findings and shared it with other stakeholders, sparking the adoption across the board. Bhuj, under his guidance, became a production powerhouse, supplying more than four lakh tons of silica sand per month currently.
Industry skepticism was one of the biggest challenges Kabra faced. It is highly risky to introduce a new material to a glass furnace. Production can be disrupted for months with only one inconsistency. However, he overcame resistance with evidence. It was a reference point of success at his factory, convincing others of Bhuj sand’s viability.
Acceptance followed when the industry saw that the quality of the glass remained the same and the costs were dropped to one-third of the imported alternatives. He converted disbelief into demand by showing results (rather than theories). It changed national sourcing trends and boosted Indian industries’ confidence in indigenous raw materials.
Kabra overcame resistance with evidence, using his factory's success as a reference point to convince others of Bhuj sand's viability
Establishing a Dedicated Silica Testing Laboratory
Since credibility lies in consistency, Kabra acknowledged that and established an in-house silica sand testing laboratory in Bhuj. Sometimes, reliance on third-party labs has meant delays and discrepancies. Real-time analysis of silica content, iron, alumina, and titanium levels would be possible only in a dedicated facility.
The backbone of quality assurance was set up by him partnering with experts from China and consulting with India’s mineral research institutions. It not only led to the validation of Bhuj sand but also helped lab owners, mine owners and processors adhere to the highest standards. By taking this rigorous scientific approach, the ecosystem, manufacturers, investors and policymakers were inspired to trust.
Kabra’s success was not just industrial. To educate mine owners, plant operators, and local entrepreneurs, he started a grassroots transformation on the value of silica sand. For several months, he personally led a team from HNG Float Glass to Bhuj, where basic processing equipment was installed, and best practices in mining was shared. His technical insight and mentorship was a benefit to early partners. He even funded initial ventures to kick-start the ecosystem.
Kabra stressed clean mining, proper washing, magnetic separation, and the use of spiral gravity separators to get rid of heavy minerals. Later, he encouraged local manufacturing to produce a self-reliant supply chain within India.
Sustainable Innovation with a Long-Term Vision
Kabra has always been firm on environmental compliance. Bhuj’s processing systems were ensured to be strictly in line with Gujarat Pollution Control Board (GPCB) guidelines. Wet processing was adopted with dust free processing to minimise air pollution, and thickening was used to minimise water consumption by only minimal top up.
He goes beyond national borders in his forward thinking. He is still investigating advanced technology and most recently travelled to China to investigate more advanced processing equipment. He wants to take Bhuj to global fame as a standard of silica sand quality.
Kabra’s groundwork has led to massive players such as Adani and Reliance setting up solar glass plants in Gujarat. Bhuj’s high-grade silica reserves are close enough to allow for cost-effective, sustainable production.
Economic Impact & the Future Ahead
Bhuj has been affected by a ripple effect of prosperity because of Kabra’s work, supported by other entrepre -neurs in the area. Thousands of jobs, stimulated entrepreneurship, and improved infrastructure have been created by the silica sand sector. In this economic boom, transporters, equipment manufacturers as well as hospitality providers have thrived. What was once waste is now wealth. The region is dotted with hotels, schools, vehicle dealerships, and service providers, all of which are a result of one man’s vision and hard work of people in the region.
The impact has been equally significant for the glass industry. Domestic price of the high quality silica sand/quartz was previously ₹6,500 per ton when imported and now it is available at just around ₹2,600 with delivery. Bhuj sand is now used by companies like Schott Glass, which produce pharmaceutical vials. This is only the beginning. In the future, he envisions Bhuj’s silica sand reaching international markets, removing India’s import dependency, and making it a global exporter of industrial raw material.
He says, “We have vast mineral resources in India. What we need is innovation, the right process, technology, and a vision to convert potential into performance.” Kabra’s journey is a roadmap to sustainable industrialization, based on science, propelled by purpose, and on a path to change the world.
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