Our Facilities
Vanguard International Private Ltd. is establishing Pakistan’s first indigenous ballistic glass manufacturing plant in Karachi. Our 30,000–35,000 sq. ft. facility is organized into specialized production zones, each designed for precision, safety, and compliance with international ballistic and quality standards
Glass Storage & CNC Cutting Area (Zone A)
This is the raw material intake and precision preparation zone. Large-format float glass sheets are stored in climate-controlled racks before being precisely cut to specification using computer-controlled systems. The area is designed to handle thick, multi-layered ballistic glass layups with micron-level accuracy
- Key Equipment:
- CNC Glass Cutting Table – Max glass size: 2440 x 3660 mm | Thickness: 2–25 mm | Cutting accuracy: ±0.15 mm | Speed: 120 m/min
- Integrated break-out bars & scoring tools optimized for ballistic laminate configurations
- Anti-scratch air flotation system to protect coated or tinted surfaces
- Auto-optimization software for maximum material utilization
- Capabilities
- Precision cutting of single and multi-layer glass stacks
- CAD file integration for complex shapes
- Remote diagnostics for maintenance
Glass Washing & Pre-Processing Area (Zone B)
Before lamination, every glass sheet must be perfectly clean. This zone uses de-ionized water and multi-stage filtration to remove all particulates, oils, and residues that could cause delamination or optical defects.
- Key Equipment:
- Automated Glass Washing Machine – Max width: 2500 mm | Thickness: 3–25 mm | Speed: 1–10 m/min (adjustable)
- High-speed air knife drying system with optional heating
- Three pairs of soft brushes compatible with low-E and laminated glass
- Multi-stage water filtration with stainless steel tanks
- Capabilities
- Heated water circulation for effective removal of fine particles and PVB residues
- Vertical or horizontal configuration to integrate with custom production lines
- Glass thickness detection system for automated adjustment.
Lamination Clean Room (Zone C)
A controlled ISO Class 6 environment where cleaned glass sheets are assembled with PVB (Polyvinyl Butyral) or EVA (Ethylene-Vinyl Acetate) interlayers. This zone is critical for achieving bubble-free bonding, optical clarity, and ballistic integrity.
- Key Equipment:
- PVB/EVA Film Layering Unit – Working width: 2500 mm | Supports multi-stack laminates (up to 5+ layers)
- Automatic laminating line with cleanroom integration
- Vacuum chamber for bubble-free lamination
- PID heating control with multiple zone management
- Capabilities
- Automatic PVB film feed with edge trimming
- Supports colored, anti-spall, and acoustic PVB interlayers
- Integrated temperature and pressure logging for traceability
- Cycle time: 15–30 minutes depending on composition
- Environmental Controls:
Positive pressure, HEPA filtration, 45–55% relative humidity, ISO 6 particulate standard.
- Compliance
- ISO 9001:2015 | ISO 45001:2018 (OHS)
Autoclave & Curing Room (Zone D)
The most critical stage in ballistic glass production. Laminated glass stacks are subjected to high heat and pressure to permanently bond all layers, eliminate air pockets, and achieve full optical and structural integrity.
- Key Equipment:
- Industrial High-Pressure Autoclave – Chamber size: 2.4 m diameter x 6 m length (customizable)
- Operating pressure: Up to 13 bar | Max temperature: 150°C
- PLC-based control with programmable cycles
- Automatic rail-based loading system for heavy ballistic units
- Capabilities
- Multiple pressure/temperature profiles for different interlayers and glass types
- Electric or thermal oil-based heating
- Forced air and water-spray cooling options
- Integrated safety valves and monitoring systems
- Safety Features
Reinforced flooring, enhanced ventilation, pressure interlock, dual safety switches, heat-resistant PPE for operators.
- Compliance
- ISO 9001:2015 | CE Machinery Directive | ISO 45001:2018
Ballistic Testing Laboratory (Zone E)
An in-house, controlled firing range and analytical lab dedicated to validating every batch against NIJ, EN 1063, and STANAG standards. This facility ensures that no product leaves without certified ballistic performance.
- Key Equipment:
- Ballistic Testing Chamber – Size: 4m x 4m x 3m (customizable)
- Doppler radar / dual-beam chronograph for velocity measurement
- Adjustable multi-angle target fixtures
- Reinforced control booth with remote firing system
- High-speed camera integration (optional)
- Analytical instruments: Haze meter, digital calipers, edge stress polarimeter, transparency meter
- Test Capabilities
- Calibers: 9mm, .44 Magnum, 7.62x39mm (AK-47), 7.62x51mm NATO, up to .50 BMG
- Test standards: NIJ 0108.01, EN 1063 (BR1 to BR7), VPAM APR, STANAG 4569
- Pass criteria: No penetration / rear spall < 2.5mm
- Witness material: Ballistic gelatin / clay
Edge Finishing QA, Packaging & Dispatch Area (Zone F)
The final zone where ballistic panels are edge-finished, inspected, labeled, and securely crated for domestic or international shipment. This area ensures product safety during transport and full traceability to end-user.
- Key Equipment:
- Edge Polishing & Grinding Unit – Thickness: 3–25 mm | Max size: 2500 x 3500 mm | 8–10 precision spindles
- Edge types: Flat, pencil, OG, bevel (custom profiles)
- Water-cooled grinding system with servo-driven control
- Automated labeling and crating line
- Capabilities
- Smooth, chip-free edges suitable for framing or encapsulation
- Tool auto-compensation for wheel wear
- Heavy-duty packaging for export (wooden crates, shock indicators)
- Labeling & Traceability:
- Each finished panel receives a laminated tag with:
- QR code linking to production batch logs, test reports, and certification data
- Certification compliance logos (NIJ / EN / ASTM)
- Date of manufacture and lot number
- Compliance
- ISO 9001:2015 | Export control laws | DEPO registration (planned)