AGI Greenpac Limited (AGI.NS) Earnings Call Transcript & Summary
July 30, 2024
Earnings Call Speaker Segments
Operator
operatorLadies and gentlemen, good day, and welcome to AGI Greenpac Limited Q1 FY '25 Earnings Conference Call hosted by Arihant Capital. [Operator Instructions] Please note that this conference is being recorded. I now hand the conference over to Mr. Miraj Shah. Thank you, and over to you, sir.
Miraj Shah
analystHello, and good evening to everyone, and thank you for joining into the Q1 FY '25 Earnings Conference Call of AGI Greenpac. Today from the management, we have Mr. Rajesh Khosla, President and CEO; Mr. Om Prakash Pandey, CFO; and Mr. Sandeep Sikka, Group CFO. So without further delay, I'll hand over the call to Mr. Om Prakash Pandey for his opening remarks. Over to you, sir.
Om Pandey
executiveGood evening, everyone, and welcome to AGI Greenpac Q1 FY '25 Earnings Call. We have already uploaded our earnings presentation Q1 FY '25 on the stock exchange website and on our website. I'm pleased to say that we started the year on a very positive note. The company total income increased by 1.7% on a year-on-year basis, increasing from INR 567 crores in Q1 FY '24 to INR 577 crores in Q1 FY '25, despite a schedule, furnaces are down for relining and de-bottlenecking. The company recorded an EBITDA of INR 147 crores, achieving 4.7% year-on-year growth with a stable margin of 25.4%. EBIT for the period amounted to INR 105 crores with a margin of 18.2%. The net profit for the year was INR 63 crores and margin of 11%. Our consistent performance is driven by operational efficiency, a strategic product mix and a focus on premiumization. Our ongoing furnace relining and de-bottlenecking project, which we initiated this quarter, is on track for completion in early August '24. With the next scheduled relining plant for FY '28, we are strategically positioned to meet the rising demand of glass containers while optimizing our operational efficiency. Now I will hand over the call to Mr. Khosla to discuss some of the key business highlights. Over to Mr. Khosla.
Rajesh Khosla
executiveThank you, Mr. Pandey. Good evening, everyone. We continue to build on our growth momentum this quarter, driven by the strategic initiatives and is set for commitment to the operational excellence and sustainability. Our state-of-the-art specialty glass plant is well positioned to capitalize on the growing demand of high-margin products, such as Cosmetics and Perfumery, driving overall profitability. We expanded our global reach through strategic participation in exhibitions across the UAE, U.S.A., Europe, strengthening our brand and building valuable partnerships. Our specialty glass plant, which commenced commercial production in financial year '23/'24 is performing well, capitalizing on the forgoing demand for high-margin products in the Cosmetics and Perfumery sector, is coupled with our continued expenditure, demonstrating our commitment to sustainability. We successfully commissioned 2.8 megawatt solar rooftop project at our Hyderabad plant, increasing the company's overall solar capacity to 19.56-megawatt. This project significantly reduced our carbon footprint, lower our energy costs and enhances the operational efficiency. AGI Greenpac's Specialty Glass state-of-the-art plant achieved the prestigious IGBC Green Factory Building Platinum rating for the underscoring of our sustainability leadership. Our R&D Center and Chemical Lab secured NABL accreditation, demonstrating our commitment to deliver high-quality innovative solution to our customers. Additionally, our Bhongir and Hyderabad plants were well recognized with Gold and Silver awards at the CII EHS Excellence Awards '23, highlighting our strong environmental performance. Our achievement highlights our commitment to stakeholder value and sustainability with the strong foundation and strategic focus, we are twice for growth and long-term success. Now we would like to open the call for any questions you may have. Thank you very much.
Operator
operatorWe will now begin the question-and-answer session. [Operator Instructions] The first question is from the line of Pranay Roop Chatterjee from Burman Capital.
Pranay Roop Chatterjee
analystSir, my first question is with respect to your unit economics over the last 3 years, FY '21 to FY '24. So simply, what I was looking at, in fact, your gross margin per tonne basis, like if I divide all your P&L numbers by your volume numbers, gross margin per tonne has grown from around INR 19,000 or INR 20,000 to about INR 30,000 per tonne over FY '21 to FY '24. What exactly has led to this? And connected to this, given that we are in a cyclical industry, the RM prices, gas prices, furnace oil prices seem to have peaked out and now started to come down. Now as you pass on these lower prices to your customers, how should your EBITDA per tonne of about INR 10,000 behave in the coming future?
Rajesh Khosla
executiveOkay. If I understand your question properly, if you mean to say, the cost per tonne, which used to be around INR 20,000 a tonne, it has gone up to INR 30,000 a tonne.
Pranay Roop Chatterjee
analystNo, no, sir. So what I mean is your revenue minus your COGS, the gross profit, that when you divide it by your tonnage. So per tonne, how much are you earning, the ASP minus your RM cost per tonne. That has expanded over FY '21 to '24, because we have managed to pass on more prices, seems like you have managed to consume more prices than the cost has increased. So what exactly is that?
Rajesh Khosla
executiveI may like to tell you that whatever is the gross margin we are talking about, it is a -- it depends on your the cost side and your selling price. So you are assuming right now that whatever increase of margin has happened, they might have happened because of the increase in the prices to the customer, which may not be the right thing to say. Because a lot of efforts and de-bottlenecking has been done on the cost side and the bottom line has been gone high, or the cost side also with the big margins. So that is the reason. But I'll be very sorry to say that we are not opening or we are not publishing our data on a per tonne basis. So my comment on the exact number on per tonne will be right thing, we are giving on the total gross numbers. So -- but the real answer is the total, our gross margin, whatever has gone up, the big part is on the cost side and other part is on the selling price side. So selling prices can be adjusted now and then, because of the change in the formula or whatever is the cost, but the real cost reduction, which has happened with the de-bottlenecking and other synergies, they will certainly be always with the company, and it will be a permanent bottom line to the company.
Pranay Roop Chatterjee
analystJust to plow on it a little further, given in gross profit, the only cost we are really talking about is your raw material and direct manufacturing costs, right, soda ash and et cetera and on the daily manufacturing costs. If you could just throw some light, because I think this has been discussed in the past couple of calls as well. If you could just throw some light on what de-bottlenecking has happened, which has led to reduction of some of these manufacturing?
Rajesh Khosla
executiveSee when you do a lot of de-bottleneckings in the capacity side or on a technology side, the total consumptions on raw material, on the fuel, on the efficiency, productivity, everything they contribute in your gross margin. So there have been a lot and a lot of projects which has been happening in with us to increase the productivity, even the efficiency. That is very important. The efficiency of your products. See, if you are able to produce, say, 100 bottles, it's not like that all 100 bottles are good to go to the customer. There may be 80% or 85% or 90%. So the economic curve will change drastically when you improve on these parameters. So these parameters have contributed a lot in giving us the gross margin.
Sandeep Sikka
executiveSo just to put forth, let's say, our efficiency on machining, the bottle 5 years back was somewhere around 83%, 84%, which as year-on-year, we have been able to increase. So that's...
Rajesh Khosla
executiveThat will substantially increase with the help of technology, additions and defective piece and our managerial commitments.
Om Pandey
executiveI can add just one point, that in the past also, we have mentioned that we have a lot fuel mix. And depending on the fluctuation in the market prices, we keep on recycling or the use of fuel from one room to the other. So this optimization of the both side on the cost side as well as on the efficiency side, it contributes directly to the gross profit.
Pranay Roop Chatterjee
analystMy next question is on generally to industry demand and supply scenario. So I've been starting how the industry has behaved since FY 2008. So I think 2008 to 2014 were the up cycle in the alcohol sector and your revenues on CAGR basis for the packaging segment grew more than 20%. Now at that point of time, the industry has fully utilized. But what happened after 2013, 2014 is, lower nuclear payments and the industry capacity is sort of more than doubled. But the remarks remain flattish because of multiple reasons. Now as we stand today, industry seems to be optimally utilized, it's basically the commentary of some of the alcohol majors. How do you -- how does the manager of the second largest government, such a industry, plan for the next 5 years in such a scenario from a growth perspective. And right now, if you can please answer this without considering the acquisition as if it was not happening.
Rajesh Khosla
executiveLet me answer with one of my comments, which I always give it to my people. So the work is always -- the commercial work is always started by the price and we bought by cost. So we always focus on the cost, because it is on the defensive side of the game. So what you have been referring in 2008 to 2014 when there was an upswing and on. So those are two type of battles and wars here. The price is fighting the war. But for the longer wars, winner if you have to win, it has to be bought with the cost. And that is exactly the answer which I've given in your earlier question, where you have been asking your gross margins have gone up. And I told that it has been -- it has grown up because of the cost side. So our efforts are there just to increase the price with the valuation, but we have to fortify about the cost part, which we are doing with the technology and best practices. So this is the way we are trying to. And beside that also, there can be a market position up and down. Yes, the whole company will be win, but we are quite resilient now to sustain the those type of double lenses.
Pranay Roop Chatterjee
analystGot it. And is this for current EBITDA per tonne sustainable, is there a downward dip?
Rajesh Khosla
executiveI think we have been with you guys for the last so many years, and we are talking the same story. So it is a sustainable year-on-year, on quarter-on-quarter, the numbers have been same, is similar or whatever we are projecting. And market risk is always there, which is in every business. No business is insulated from the market risk. So market risk is there. But besides that, I think from the operational side, the commitments are always there to make it sustainable.
Operator
operator[Operator Instructions] The next question is from the line of Abhishek Jain from Alfaccurate.
Abhishek Jain
analystCongrats on the different set of numbers, despite a few hurdles on the production. The first question is on the volume and the realization side. So how was the first quarter volume and the realization? And second that, how do you see the volume growth and pricing trend there?
Rajesh Khosla
executiveThe first question is, you are looking for our comment on volume and realization.
Abhishek Jain
analystYes, in the first quarter.
Rajesh Khosla
executiveOkay, first quarter. Since we are not giving the volumes in our -- any of our declarations, so FX volume or FX metric tonne we are not offering in our publication. But I can just give a small view on that. First quarter was a little difficult for the sales, because of the elections. So there have been some prohibitions and restrictions on the consumption of one of the biggest segments in our glass industry, liquor and beer segment and alcoholic segments. So the numbers what we could have done or we could have achieved are slightly less than what actually has happened. This is the part of the market reality, and we have to face it. Regarding [ systems ] realization is more or less flat. It has been more or less same as it has been the earlier one with a small adjustments on reprice because a major part of our supplies are adjusted with the formulas.
Abhishek Jain
analystAnd how is the pricing trend looking a lot of the increase in the pricing on the glasses, mainly because of the supply side issues. So -- just if you can throw some more light about this?
Rajesh Khosla
executiveSo you mean to say there has been some supply issues in the market, so prices might have gone up. You mean to say like this?
Abhishek Jain
analystYes, yes.
Rajesh Khosla
executiveSo it's not like that. There was -- there is a reasonable level of capacity available in the market. And secondly, as I told you, the first quarter was during an election time where the demand was little suppressed and supplies were normal. So there is no such skewness towards the demand supply gap. So it has been quite normal. And since we have a long-term contract, understanding with our customers, so we have been less impacted with such demand supply scenarios.
Abhishek Jain
analystOkay. And sir, currently you have added the capacity of around 154 tonnes per day in your specialty labeled glasses. So assuming that 1,800 tonnes per day capacity and adding another 80 tonnes per day capacity exactly and another 54 tonnes per day capacity for the special glasses, what would be the total capacity for the year?
Rajesh Khosla
executiveOur capacities are same as of last, we are just de-bottlenecking to extract maximum out of those capacities.
Abhishek Jain
analystSo what is the current capacity per day -- tonnes per day?
Rajesh Khosla
executiveThe same as we have been publishing on our website and everything, but we are expecting more glass by way of technology, productivity and other such efforts. So we are expecting or utilizing the glass furnaces or exploiting the glass capacities much more than the using. I can say like that, in some of the furnaces, we are running with more than 100% of the rated capacities with the debottlenecking.
Abhishek Jain
analystAnd how much increase in capacity because of these sort of the advertisers?
Rajesh Khosla
executiveAs we explained to you by de-bottlenecking, we have done that close to 100 tonnes last year. And you are talking of 154 tonnes, which is a Cosmetic plant. Here, we have added a new line. We have added a new line and de-bottlenecked that capacity also by having around 30 metric tonnes more.
Abhishek Jain
analystOkay. So last year, it was around 1,700 tonnes per day. You have added 100 tonnes and again 154 tonnes for the special glasses?
Rajesh Khosla
executiveFor the original one.
Abhishek Jain
analystOriginal one. Right. So that would be around 1,950 plus something, if you add anything?
Sandeep Sikka
executiveSo the base capacity, what Mr. Khosla has said, the base capacity remains at a figure of somewhere around 1,600 tonnes, but it can get extended if we use exploit the furnace. That's how it is technically configured.
Abhishek Jain
analystOkay. And my last question on this -- and in the time [indiscernible] acquisition, what is the progress there?
Sandeep Sikka
executiveSo the matter is subsidized and it's in front of Supreme Court and NCLT. Hearing is expected in middle of September. So we feel that now it should be sorted out for us in October, at the earliest. And after that, I think we can move ahead and then complete the acquisition.
Abhishek Jain
analystAnd would you require any CapEx for this acquisition?
Sandeep Sikka
executiveSo these are all parts of the resolution plan, which I can't disclose on the call right now.
Operator
operatorThe next question is from the line of Miraj Shah from Arihant Capital.
Miraj Shah
analystJust to clarify regarding the volume part that you just mentioned. Earlier, we had 1,854 tonnes in which 154 tonnes was the specialty unit. In that, we de-bottleneck one furnace of 270 tonnes per day capacity in which we are adding roughly 80 tonnes. Besides that, is it -- did I hear it correctly that, we've also added another 30 tonnes in the specialty units?
Rajesh Khosla
executiveI think so, let me put the numbers in a right way. 1,600 tonnes is the capacity, which we had the initial capacity and 154 is whatever we have added up. So once you start running the furnace out of 154 tonnes, we have de-bottlenecked 30 metric tonnes further in specialty glass, and we have de-bottlenecked 100 tonnes in the commercial glass. So this 1,600 tonnes plus 100 tonnes, 1,700 tonnes plus 119 tonnes or 118 tonnes, you can call it. So [ 17, 18, 19, ] so it is a share below 1,900 tonnes. So the new furnace, which we are building up, we have de-bottlenecked by 70, 80 tonnes. We expect that the furnace is going to behave and to give us the output, which is more than the earlier one. But these are all technological efforts. We hope so that when we will start taking out the glass, it is going to be nothing more glass than what we have been earlier taking out and as per our plan of around 70, 80 tonnes more than the earlier capacity.
Abhishek Jain
analystOkay. So current capacity would be just under 1,900 tonnes, right?
Rajesh Khosla
executiveAgain, I'm saying the capacities are defined by the furnace supplier. And exploiting the furnace with the highest possible capacity, which is a job of the manufacturer. So capacities of these furnaces remain same as earlier, but the exploitation is much more or we are using exploitation maybe negative growth, I can say, but we are expecting the glass much more than the rated capacities.
Abhishek Jain
analystOkay. Understood. Understood. Okay. And just one more question before I get back in the queue. Sir, if let's say, you have a land and on that land, if you want to do a brownfield CapEx, starting from all the way from ordering machines. So roughly how much time will that take from the moment you end or do the machines do the commencement of the facility?
Rajesh Khosla
executiveSee, it all depends upon so many factors, but you can say anywhere between 2.5 years to 3 years should be the normal one.
Abhishek Jain
analyst2.5 years to 3 years. Okay. Okay, I understood. That's it from my side. I'll get back in the queue.
Operator
operatorThe next question is from the line of Darshan Jhaveri from Crown Capital.
Darshan Jhaveri
analystAnd all of my questions have already been answered. So I just wanted to understand currently, like in terms of operation terms, we had because of the shutdown, we had some lower capacity utilization than what our norm is. So, now in the going ahead quarters, can it come back to what we used to do of near 94%, 95%? How would it pan out?
Rajesh Khosla
executiveYes, you are right. So once the furnace will start delivering the glass. So our capacity utilization will be the normal one as we used to have.
Darshan Jhaveri
analystOkay. Perfect. And sir, just wanted to get after being at such high capacity utilization, what kind of maybe revenue could we see right now? Because with the de-bottlenecking, we will get some benefits. So currently, like quarter or revenue growth could we expect in FY '25, sir?
Sandeep Sikka
executiveWe expect -- I think, we have given a guidance that we should be able to maintain our growth of around 10% with the current existing facilities by way of debottlenecking, enhancing productivity, enhancing product mix. So we just hold on to that, that then was -- some growth with the existing facilities is a viable option.
Operator
operator[Operator Instructions] The next question is from the line of Pulkit Singhal from Dalmus Capital Management.
Pulkit Singhal
analystMy first question is on the demand from the alcohol industry, again particular figure. My understanding is that some of these MNC players have actually switched from glass to pet bottles at least for the lower end brands in their portfolio. So just wanted to get your view on what kind of risk of shift away from glass can one foresee, because alcohol is the big segment. Obviously, for beer, it is not there as much. But I'm talking about particularly spirits. And what kind of demand do you see from product industry over the long term, given this kind of substitution risk?
Rajesh Khosla
executiveIf I pick up the numbers from the public domain, and whatever is being published in the newspaper or maybe in other news items, the alcohol industry is growing by around 8%, 9% numbers. So this 8% to 9% number and the alcohol industry has to expect the people, the different segments of the people with the new packaging ideas whatever it is possible. So we bet the first. So there are two types of plastics, which was being used in the -- by the alcohol people. One is a very generic type of plastic and one is a high-end plastic, which has been used in view of glass, which is even more expensive than the glass. So there is a novelty sector, which has attracted the glass, attracted the people and novelty factor has a time line or they have a life and which we have to expect that. So what we expect that these type of conversions or these type of switching and swapping common is very common. Is very common. It has been happening earlier also, it is happening now also. So it is not about matter of a very big concern. But secondly, the whole industry is well quite. And I think so. So even after the conversion and there is a growth in the liquor market, particularly everything looks to be almost the same stage as it used to be. So we are not much concerned. It's a normalcy. And as a glass industry, I think we have to bring more innovation, more novelties to make sure that more and more conversions and attraction happens towards the glass. So this is what is normal, sir.
Pulkit Singhal
analystUnderstood. Second question is from a supply side on a quantity, intensity perspective. So at one end, obviously, HNG as a competitor has kind of gone down and they are doing what they're doing when they required. But at the other end, we've also had, the Khairatabad cluster, which earlier was not well penetrated in this segment, but seems to have kind of got its share within the MNC manufacturers as well. And they seem to be doing well. Now the question is how do we compete with someone in that cluster, because they have a much more favorable pricing in terms of gas, et cetera. So what's your views on that?
Rajesh Khosla
executiveSo now you're talking from the supply side of that. So if I understood your question very well, you are asking me how you are going to strategize your fighting or competition with people like Firozabad people?
Pulkit Singhal
analystYeah. Sorry. Firozabad people.
Rajesh Khosla
executiveFirozabad people. Okay. See, the market is well poised, and glass is a very straight sensitive market. So we are basically placed in the Hyderabad side and we are keeping to all the year by or all the possible industries here. And besides that, our technology -- our products are so superior technologically. So we have been innovating, putting up the new technologies and everything. So that the right type of product goes to the customers. So if I can say very well, we are also one of the most preferred companies on the glass side, where the people prefer to have our glass as compared to anybody's glass in the competition. So we are giving a value back to the customer, and these values are in form of the product quality in form of the straight part in form of the commitments, in form of the timely, these things. So these things add up and give a total integrated products, which is basically gives the value to the customer. So I think we are not much concerned. Okay. We are keeping the eyes, but we are not much concerned on these parts because our clients, our customers, they are quite committed because we have been giving technological products to them.
Pulkit Singhal
analystUnderstood. Just a last question on the longer-term export opportunity out of India for glass, and I'm not talking about the next 2, 3 years. But has there something changed in the overall -- I mean, basis your study on the overall glass sourcing market globally that allows India to be more competitive now than it was earlier?
Rajesh Khosla
executiveOkay. I can give you this answer. China Plus One policy. Number one. The average age of the people in Japan is 50 years. The average age of the people in U.S. is 38 years. The average age of the people in Europe is more than 40 years. So the working people will be quite less and there will be more on the leisure side of the life. So obviously, the growth potential from India, with China Plus One policy is there. I'm not talking with respect to glass, but it is with respect to everywhere. And secondly, that glass be a little more energy intensive, a little more industry, which is countries like India will be able to sustain more better way, so the potential exists and potential will grow in the glass industry for the export purpose, in the times to come.
Operator
operatorThe next question is from the line of Vijay Agarwal from [ Secom ] Family Office.
Unknown Analyst
analystYes. Yes, sir. Congratulations on a good set of numbers. In context of the previous question, I will ask how long is it takes for a brownfield actually to set up? So could you also just give us an idea of the cost per tonne on a brownfield project versus a greenfield project? And also in terms of the timeline you may put for brownfield, how long will it take for someone like a fresh person to come into the industry and set up the capacity?
Rajesh Khosla
executiveThe answer is -- to answer in one particular line will be too much, because it all depends upon the project management side. There are few projects which has been taking quite a long time when you are not able to finish and few people are able to do a little faster on that. I think for all practical purposes, you should take anywhere between 2.5 to 3 years is a reasonable period in which they're very standard, they're very up-to-date and very techno study projects can be implemented. So this is the timeline. Now you are talking of per tonne, this is of how much is the CapEx cost on that? Again, very difficult because it all depends upon what type of machines you are buying, and what type of products you want to cater. So if the product -- for a product mix of A, will cost you INR 100 a product mix of this will cost of you INR 170 also. So it all depends upon the -- on your type of products, on the type of machine, technologies and other things, what you are looking for. So two ways answer to be given like that, as on -- at this point of time.
Unknown Analyst
analystSo sir, just to empathize the same question again. So in 2019, you had done a greenfield CapEx of 100,000 tonnes. I think it cost you INR 75 crores, and you have done recycling investment as well of another INR 150 crores. So if one could get an idea of the same capacity today based on commodity inflation, what would be the same cost of that CapEx if I wanted to do that today?
Rajesh Khosla
executiveIf I understand your question, you're talking INR 130 crores of CapEx you're talking about. Am I right?
Unknown Analyst
analystNo, no, sir. So in 2019, you have done a greenfield CapEx up to INR 75 crores. And you have also done a recycling investment in technology for INR 130 crores. So cumulative announced our foreign income investment was done for 100,000 tonnes per annum capacity. In that same capacity today based on some commodity price inflation, what would be the same CapEx that we have to do it in today's time, the cost?
Rajesh Khosla
executiveI think, I have to relook to your numbers, what you have been telling me in 2018 -- '19, I mean to say, with a CapEx of INR 275 crores you are talking, because most of our complex, they are the integrated list of further relining. They are the integrated list of the other technology upgradations and everything. So to me and to the best of my knowledge, there is no such new furnace, which has been added in 2019, but there has been the furnace rebates which has been done. So I have to relook to the CapEx number again, and the breakup of those numbers like that. So -- but there is no such greenfield projects we are talking of adding. But in 2019, if you are referring to some of these technological upgradation, where we converted fuel furnace from our normal fuel furnace to the specialty furnace to make the beers and to who we have invested in the new lines. Okay. That is a separate thing. That is just a technology upgradation on those furnaces.
Unknown Analyst
analystAnd one last question. So generally, call it, in terms of pricing, how does it work? I mean percentage uses for AGI versus the broader industry as a raw material, what is the percentage usage that maybe we do versus the broader industry? And is there some price sort of parity over there or some cost comparison versus the virgin material?
Rajesh Khosla
executiveI'm using place more than areas. So in Europe, this percentage of collect is 90%. In U.S.A., it is 65%, in India it is 50%. And in other countries, it ranges from these things. It all depends upon the collection system. Now in India, the collection system has been quite poor, and we are restricting ourselves less than 50%. And AGI is also using close to 50%. In some furnaces, it is a little more and in some it is less. So it is -- you can say it is 50%. We want to use more and more, but you know sustainability efforts, collection system, all are going to dictate how much connect we can use. Furnaces are capable to use up to 90%.
Unknown Analyst
analystGot it. And sir, what would be the -- from a price perspective, how much more favorable would it be to use connect versus the virgin raw material?
Rajesh Khosla
executivePractically seen -- practically the price of connect and the price of virgin raw materials is almost same. But sometimes, it all depends because using more connect is good for sustainability. It saves a bit of energy also, easy to melt also. So all those parameters, which are non-commercial parameters, they are also important. So that is the reason connect is always a preferrable thing.
Unknown Analyst
analystOkay. And sir, if I may just squeeze in one last question. So like you mentioned, brownfield would take 2.5 years -- it's you really go through [indiscernible] 2.5 years of fresh capacity, but there's also a lot of spare furnaces in the capacity line in the industry. So if one had to maybe touch on that, like example, you mentioned HNG does have that spare capacity? So I wanted to realign, restructure good capacity, how much time would that take on versus setting up the brownfield more fresh capacity?
Rajesh Khosla
executiveSee, when you say brownfield, there are different types of brownfields we have been talking. One brownfield means you already have a furnace, sorry -- you already have a land, straight away you start constructing. So these are modular type. The second brownfield is basically, you have to -- then you are relining your furnaces, you increase the capacity or de-bottleneck something. So it all depends upon what type of brownfield we are talking. If you are talking about a new furnace on the same land, then you are saving only the land hunting time. That's all, nothing else. And I have assumed the land hunting time only for 2, 3 months only in the normal greenfield project.
Unknown Analyst
analystAnd just so, I wanted only realign -- reline and restructure the furnaces, then we would assume somewhere around 6 to 8 months?
Rajesh Khosla
executiveAgain, see, you have to plan and you have to wait till the relining comes and the relining will take you 1, 1.5 month extra than the normal relining.
Operator
operator[Operator Instructions] The next question is from the line of Chirag Jain from Yogya Capital.
Chirag Jain
analystSir, just two quick questions. First on the Specialty segment. So can you give us a number what was the utilization rate for specialty segment?
Rajesh Khosla
executiveUtilization rate is close to 70%.
Chirag Jain
analyst70%. Sir, are you looking to expand contract?
Rajesh Khosla
executiveYes, we are looking to expand, but it all depends upon, first, we were going to utilize this furnace from 70% to 100%. And then certainly, we will be like to go for that. So market of Cosmetics, which is again in a public domain is going up, and there is an opportunity. So obviously, we will like to tap the opportunity. So first, we would like to utilize the furnace. Then second is, we like to de-bottleneck the furnace. That is the second step. And third then we have to rethink on any of the green or brownfield later on.
Chirag Jain
analystPeer of ours started similar segment around same time. They are expanding it by around 50% with similar capacity. So why we aren't being able to increase our capacity utilization rate?
Rajesh Khosla
executiveCan you repeat again, please?
Chirag Jain
analystOur peer started a similar facility in Cosmetics segment. Okay? With 160 tonnes per day, okay? And now they are expanding it by 95 tonnes per day in the same Cosmetics segment. So why we haven't been able to ramp up our capacity utilization? That is the main question.
Rajesh Khosla
executiveOkay. If you are talking of one of the competitors say they are -- they have put up the facility of 160 tonnes. This facility name, there is no problem because I will understand better, with the numbers.
Chirag Jain
analystHaldyn Glass.
Rajesh Khosla
executiveNo, I don't think so. This is right. There are two separate companies. One is a Haldyn Company and second is a Haldyn Heinz Company. In Haldyn Heinz Company, as I understand from the public domain information, their furnace was around 70, 75 tonnes and when they had replanned the furnace, they increased it to 95 tonnes, sometimes -- not even 95 tonnes, around 80 tonnes or something like that. So 10 to 15 tonnes increase has been there in the company Heinz. Second part is Haldyn. So Haldyn is, they are producing the normal lab. But for specific time, they convert that furnace with the raw materials to the specialty glass. So the furnace is same as of the normal glass. But with the some campaign they take it for the specialty glass. So it is not like that they have added any furnace or something like that, it's not there.
Chirag Jain
analystSir, last question, if I may squeeze in. I just wanted to know, what would be the cost to reline a furnace of 100 tonnes per day, for example, which is operational currently?
Rajesh Khosla
executiveOkay. Too difficult a question to answer to me, it all. Again, I'll answer a bit of that to make you understand better. It again, it depends upon what type of refractory you are using, what type of other jobs you are going to use during this shutdown? What are the new dimensions or the new technological things you're going to add up this in the furnace. Are you going to little de-bottleneck? So show any thing, but if you ask me very plain type of vanilla type of relining the furnace, I think the 100 tonnes will take down INR 25 crores to reline the furnace.
Chirag Jain
analystOkay. And if we kind of want to convert the lower the cost of fuel and power costs. So adding that, what would be the cost?
Rajesh Khosla
executiveSee, I don't understand, please. Can you repeat?
Chirag Jain
analystSo for example, power and fuel cost for that furnace is around 50%, okay, for example. So we want to reduce it to around 20%, which is our level. So what would be the cost for that combined with the relining?
Rajesh Khosla
executiveSee when you reline the furnace, obviously, because when you use any of the fuel, the fuel has two parts, once it goes to the glass to multi-glass. Second, it got reflected outside and it's a wastage. So practically, when you reline the furnace, all that wastage you try to collect that and your fuel consumption goes down. So this is a very normal thing which has to happen. But if you're talking beyond the normal, then those are the different technologies, which we have to add up. Say for example, somebody wants to oxygen control systems and other things. So then it all depends upon this type of technology, you are choosing -- and from where you are choosing and then it will have the venue accordingly. But for the normal relining, the fuel consumption will certainly come down, because you will have the less wastage as compared to other things, earlier one.
Operator
operatorThe next question is from the line of Miraj Shah from Arihant Capital.
Miraj Shah
analystJust a couple of questions on the industry size. In the last call, you had mentioned that the industry size was roughly 11,000 tonnes. Was this the capacity of the industry or the demand? And does this include the perfumes and wellness segment as well or just alcohol segment?
Rajesh Khosla
executiveOkay. Last time, when I say 11,000 tonnes, I'd like to put it on record there, because the industry is operating with the different numbers, and there is a lot of, you can say a small scale industry or a lot of unspecial industry is there. So those numbers are not very visible. So these are just the estimates and guesstimates for us that the industry must be operating with these numbers. So I think, so, now -- so this is one clarification on that number. Your question was, can you repeat the question again, please?
Miraj Shah
analystYes, sir, whether this approximate figure of 11,000 tonnes, if it is the demand of the industry in India? Or is it the supply capacity?
Rajesh Khosla
executiveNo. The capacities are much more. The capacities are much more and much more than the -- these are the running capacities, I mean to say, but the actual capacities are much more.
Miraj Shah
analystOkay. So this is the operational capacity in the industry?
Rajesh Khosla
executiveYes. Operating capacity.
Miraj Shah
analystYes. And this includes for wellness and health care also, this is purely for Alcobev segment?
Rajesh Khosla
executiveNo, no, this is normal, for channel, everything all put together.
Miraj Shah
analystSo this would also include PGP glasses capacity as well in that?
Rajesh Khosla
executiveI think so. With my strategy people, they have included everything put together. So these numbers are the same. If you -- we should catch up the numbers from some other sources, maybe those numbers are a little different. But at a different point of time, the numbers may be different. For example, like our furnace was not working for last 3 months. If somebody catch up the number at that time, probably that number may not be there in that calculation. So that's the reason I say different numbers at a different time, and those numbers are also just the [ ASA ] number. So somebody has to pull the data. So there is no such organizations like [indiscernible] mobile organization, which catches the exact number and publish it.
Miraj Shah
analystUnderstood. Perfect. Okay. And sir, secondly, just wanted to understand on the Firozabad belt, the players are over the -- the players that are in the Firozabad belt, what will be the capacity, total capacity of that area? That is one unorganized association altogether.
Rajesh Khosla
executiveSir, it's a very million dollar question. I think those capacities are not understood and available to us. And -- but roughly, roughly, I can say those are maybe -- may have an operating capacity of around 2,500 tonnes a day.
Chirag Jain
analystI'm sorry, can you come again?
Rajesh Khosla
executiveThey may have an operating capacity of 2,500 tonnes a day.
Miraj Shah
analystOkay. The operating capacity of 2,500 tonnes. Okay. Perfect. And just lastly for in -- I think in Q4, one of the HNGs facilities were shut down because of fire. So as of today, could you just give me a rough estimation, what is the volume in HNG right now?
Sandeep Sikka
executiveWe don't get this information from HNG. Because the unit is still not with us. So I think you have to see the website of HNG, in their data, and the data they have to upload [indiscernible]
Operator
operatorThe next question is from the line of Pranay Roop Chatterjee from Burman Capital. Hello, Mr. Chatterjee, your line has been unmuted.
Pranay Roop Chatterjee
analystYes. So I have a couple of questions. My first question is you mentioned that the operational capacity is 11,000. Would you have any sense on how much the total industry utilization would be like, is there spare capacity available to increase sourcing without any major CapEx? And any new capacity announcements that you have heard of by existing or new players because. Yes, that's it.
Rajesh Khosla
executiveSir, I'm not in a position to say what is the total capacity, but total capacities, which I can say the government capacities are higher than the operating capacity, it is sure. The second thing is that which we hear, here and there every time that somebody is like to put here capacity out there. I cannot comment on that, because if there is somebody who publicly announced only those capacities can be we can officially sell at such a platform. So I say so, there is any such in a formal structure manner, it has come to the public domain information. It is all industry here and say, so which is yet to be verified. So I don't see any very big number, which is floating in the market.
Pranay Roop Chatterjee
analystSir, very fair point you make, I personally also could not find any large announcement, but let me ask the question differently. Right? So you mentioned the figure -- you mentioned a couple of things, right? You mentioned 2.5 years would be a good benchmark. The new guy who wants to create a brownfield or greenfield, would take this much time to -- from in order to commissioning. And then you also said that the government capacity in the industry is more than the operating capacity, right? Let's say, if I -- sitting here right now, talking to you, I want to start [indiscernible] what would be logical for me to do? Buy one of the government ones, reline it, because that's faster or to wait for 2.5 years and do a long [indiscernible] and do you see a risk of overcapacity?
Rajesh Khosla
executiveLet me first clarify you what is the meaning of government capacities. So government capacities are two types of capacities. One is the furnace is not working. It is shut down and already not operating, so somebody can restart the furnace, which you are talking of buying the capacity and using it. The second government capacities are when somebody is underutilizing the furnace, so he's not -- he doesn't have the spare capacity available. I mean to say, spare furnace available. Within the same furnace, it's not able to utilize the 100%. Maybe because of the condition of the furnace is not good, maybe because he does not have the enough orders, maybe for any other reason or technological or de-bottlenecking he has not done that. Because sometimes the furnace is capable, but the machines are not capable. So because of all those mismatches, those capacities remain government. So government is furnaces closed. Government is furnace is underutilized. So if restores, you can certainly buy, but if it is underutilized, nothing can happen, only that guy has to do himself to make it proper.
Pranay Roop Chatterjee
analystAnd hence, do you see a risk of overcapacity in the industry...
Rajesh Khosla
executiveNumber one, glass is a big voice game, where somebody has to put a lot of money to start the capacity. So somebody cannot -- I don't think so somebody will just put the money without thinking. Otherwise, it will be societal for him. And of course, it can affect the other guys also, but it is more societal for the person who is going to put the money without any thinking. So it can simply have the much bigger consequences on that. So I think so. I feel like that in the industry, the people are quite intelligent, prudent and they may not like to spend the money unless until it is backed by the demand and supply scenario.
Operator
operatorThe next question is from the line of Abhishek Jain from AlfAccurate.
Abhishek Jain
analystYou had a plant shutdown in first quarter and that impacted your sales. So how much has you lost because of the shutdown in the plant?
Rajesh Khosla
executiveSir, we were not able to produce 16,000 tonnes of glass in this quarter. Because of this. I'm talking quarter. So my quarter ends on 30th of June. Because part of the shutdown has spilled over to the next quarter also, but we are talking till 30th of June, we lost 16,000 tonnes.
Abhishek Jain
analyst16,000 tonnes.
Rajesh Khosla
executiveSo it's 16,000 tonnes. So you may like to understand on the revenue side?
Abhishek Jain
analystOkay. And it will continue in the second quarter also or it will reduce?
Sandeep Sikka
executiveThe whole 40, it doesn't mean that it's a lot of revenue, because generally there are seasonalities involved in the businesses. So we keep producing to meet stock for certain and then like beer season or the liquor seasons are different. So what Rajesh is trying to say, we lost 16,000 tonnes -- I don't know, 18,000 tonnes. It's a planned one.
Rajesh Khosla
executiveIt's a planned one. It's a planned shutdown. It's not like that there's something breakdown and we lost something. It's a planned properly planned. For 2 years back also we have planned for this shutdown.
Abhishek Jain
analystOkay. And how much it was compensated by the pricing, because the last quarter pricing was very low, I think that there was -- it was prices have started to [indiscernible] by 5, 10 basis. So is there any improvement on the realization fund? Because in this quarter also there was a higher value-added product, as you mentioned.
Sandeep Sikka
executiveSo our prices have more or less remained stable during this period because raw materials are also stabilized. So we are not seeing much changes in the overall realization on quarter basis.
Abhishek Jain
analystSo as you mentioned that it is also depends on the pay rate as well, and it's quite sensitive. And pay rate has gone up for the shipping rate has gone -- so it not impacting your RM prices?
Rajesh Khosla
executiveBecause we are not in the export market as such in a big way, we are just close to 10%. So it has not impacted much on the sales side. On the raw material side, only one of the raw materials, which is being imported, and they are locked with the long-term contracts, so we are getting it delivered material in our plant.
Abhishek Jain
analystOkay. And my last question on this, how much the current base in the balance sheet? And how much increase is expected both HNG acquisition?
Sandeep Sikka
executiveYou voice is not clear. Can you ask again?
Abhishek Jain
analystSir, how much the current borrowings in the company, late date?
Sandeep Sikka
executiveINR 440 crores.
Abhishek Jain
analystIt is net debt, right?
Sandeep Sikka
executiveYes.
Operator
operatorLadies and gentlemen, that was the last question for today. We have reached the end of the question-and-answer session. I would now like to hand the conference over to Mr. Miraj Shah for closing comments.
Miraj Shah
analystYes. Thanks a lot for the opportunity to let us host you once again. Back to the management.
Sandeep Sikka
executiveNo, I'd just like to thank everybody who was on the call today. I think it was very interactive. And I hope we were able to answer most of the questions. Thanks for joining.
Operator
operatorThank you. On behalf of AGI Greenpac Limited, that concludes this conference. Thank you for joining us. You may now disconnect your lines.
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