Empire Ascension: The Rise of the Fated One-Chapter 238: Glass production Part -1

In India, during the 16th century, glasses were expensive but commonly popular among upper castes, rich merchants, and noble families. Being a nature-friendly item that could replace metals and provide both a lustrous attribute to the item, it was a must-have necessity.

But unlike Europeans, who had discovered the variation of glassmaking for optical glass, it was not yet prevalent in India by that time. Thanks to these items, the European Renaissance boomed, where they made major contributions in the fields of astronomy, navigation, and information exchange. Meanwhile, Indians were limited to the domestic application of food bowls or jewelry for common and daily uses.

Having memories of his past life, Aditya wanted to start his own optical glass manufacturing in India ahead of its time. However, he only had theoretical knowledge. He hadn’t studied European glassmaking designs and, as such, couldn’t reinvent anything new for it. That’s why he felt the need to rely upon existing glass technology and find more clues. Thus, he ordered the purchase of a good glass manufacturing plant. However, he got a shock when he heard that the furnace had exploded, as it was the core apparatus in manufacturing.

"What? The furnace exploded? What is the plant’s condition now? What about the labourers?" he asked frantically.

Ashutosh cleared his throat and explained, "It’s nothing major, Your Highness. Out of 12, only one exploded, and the damage to the building is not that substantial. However, four workers working nearby got seriously wounded. They are being sent to the local infirmary after urgent emergency treatment."

Everyone sighed, as the damage was not to a great extent. However, the unfortunate news of injuries to the workers was disheartening because they were skilled artisans, and losing them was a big setback to the manufacturing process. To not take any chances, Aditya and his group rushed to the glass production plant along with Ashutosh.

Budhpur village, glass manufacturing plant, afternoon

In the outskirts of the village, a fortified area enclosed by iron bars served as a boundary, housing six modest-sized buildings that operated as a glass production factory. Outside, a column of bullock carts stood waiting, loaded with raw materials being carefully unloaded by workers.

Mounds of sand and clay lay outside the facility, while inside, twelve additional structures built of brick formed the heart of operations. Dome-shaped furnaces were positioned in open spaces to facilitate the production process. The workers moved in a synchronized manner, fulfilling their assigned roles with precision—transporting raw materials, managing tools, and securing the finished products.

However, their routine was interrupted by a commotion at the entrance. Prince Aditya and his entourage had arrived, drawing the attention of everyone present.

At the gate, a slender man with a dark complexion stepped forward to greet the prince. "Welcome, Your Highness. We have been awaiting your arrival."

As the man approached, Bheem, Aditya’s royal guard, instinctively stepped forward, his piercing glare warning the stranger to maintain a respectful distance. Aditya, however, waved Bheem off, signaling him to stand down.

Ashutosh stepped in to introduce the man. "Your Highness, this is Govind Das, our chief artisan. He has been overseeing the factory’s operations for seven years."

Aditya nodded in acknowledgment and asked directly, "Show me the explosion site."

Govind bowed slightly. "This way, Prince."

He led the group to the rear of the facility, where one of the furnaces had exploded. The air was heavy with the smell of burnt wood and clay. Workers were busy cleaning up the debris, while raw materials remained scattered around the area.

Aditya scanned the surroundings, his sharp gaze taking in every detail. "Reason?" he inquired.

Govind hesitated, beads of sweat forming on his forehead. "The kiln used in the furnace was damaged. It had a minor crack, but we underestimated its severity. Normally, we replace kilns monthly basis, as they wear out due to the extreme temperatures. However, the new kiln we ordered was damaged during transportation. Since the crack seemed minor, we took the risk to avoid production delays."

Aditya’s expression darkened. "So you knowingly used unstable materials for production?"

Govind lowered his head, guilt evident in his posture. "It was a misjudgment, Your Highness. This has never happened before, and we’ve occasionally used cracked kilns without issue. I take full responsibility for my oversight."

Aditya’s voice rose, his frustration evident. "Negligence of this scale is unacceptable! Do you realize the consequences of your actions? What if it had been you instead of those injured workers?" Turning to Ashutosh, he commanded, "Clear his payment and remove him from this factory. I do not want to see his face again."

Govind fell to his knees, his voice trembling. "Forgive me, Your Highness. It was a mistake, but I meant no harm. I’ve never treated anyone unfairly and have always worked for the company’s best interests. Please, grant me one last chance. I swear this will not happen again.

Ashutosh stepped forward, his tone placating. "Your Highness, Govind is one of our most skilled artisans. This was a grave mistake, but his experience is invaluable. Losing him would set us back significantly."

Aditya hesitated, as he thought. ’If I let him stay without punishment, it sets a poor example. But I still need these glasses for my telescope... what to do?’

Finally, he spoke in measured tone. "So, how will you take responsibility for this mistake?"

Govind, visibly relieved but still anxious, replied, "I wish to personally compensate the injured workers with six months of my salary. It is five times what a regular artisan earns. Please allow me this chance to prove my worth."

Aditya considered the offer. After a pause, he said, "Very well. I will not dismiss you for now, but you will step down from your position until the investigation is complete. Ashutosh, appoint someone else in his place temporarily."

Govind bowed deeply. "Thank you, Your Highness. I will not fail you again."

As Govind left the area, Ashutosh summoned another artisan, Harihar Pandey. A man in his mid-thirties with a lighter complexion and a burly build, Harihar approached nervously, bowing respectfully. 𝕗𝐫𝚎𝗲𝘄𝐞𝕓𝐧𝕠𝘃𝕖𝐥.𝐜𝚘𝚖

"Your Highness," he greeted, his voice steady despite his unease.

Aditya spoke, his tone sharp and precise. "Explain the process of glass production here. Be concise."

Harihar straightened, gathering his thoughts. "We begin by sourcing fine sand, soda ash, and clay. These raw materials are carefully measured and mixed in precise ratios. The mixture is fed into the furnaces, where it melts into liquid glass at extreme temperatures. Artisans extract the molten glass with iron rods and shape it while it remains pliable. Some use wooden molds, while others employ freehand techniques for custom designs. Once cooled, the pieces are refined—edges are smoothed, and surfaces are polished."

Aditya nodded, listening intently. "And how do you ensure the quality of the glass?"

"Through experience and precision, Your Highness. The artisans are trained to observe the color and consistency of the molten glass, making adjustments as needed to maintain quality."

Aditya raised another question. "Since you mentioned the mixture, how are the raw materials mixed and refined before the actual process?"

Harihar smiled respectfully. "Instead of explaining, Your Highness, it would be better to show you. It will make the process clearer."

Aditya inclined his head. "Very well. Lead the way."

Harihar guided the group to a building where raw sand was being processed. In one section, workers carefully scooped sand from a large heap and washed it in wide bowls, manually rinsing it with filter tools. The process was repeated three to four times until the sand was clean and free of impurities. The purified sand was then transported to a separate area, forming a new pile ready for use.

Harihar described the process as they moved to other buildings. For clay, workers kneaded and filtered it thoroughly, then soaked it in water to break it down. The mixture was strained through fine cloth to remove grit. For ash, it was crushed and sieved with specialized tools to ensure the particles were fine and uniform.

Finally, Harihar brought them to the mixing chamber. "Here, the materials are combined in a fixed ratio—45% sand, 15% ash, and the remainder clay. For colored glass, the proportions are adjusted, and natural ingredients like banyan tree ashes, neem leaves, sandalwood powder, or even powdered rubies are added."

Shallow trays and mixing paddles were used for the process. Harihar pointed to the four dedicated mixing stations, each overseen by the crew in charge of a furnace. Once mixed, the materials were transported to dome-shaped furnaces outside.

"These furnaces," Harihar explained, "are used to pre-refine the mixture in preliminary kilns. Afterward, the material is transferred to the main kiln for preheating. The molten glass is then molded into desired shapes before being transported to the warehouse."

With a polite bow, Harihar concluded. "That is how we process glass, Your Highness."

Aditya observed the setup thoughtfully. So far, the quality of the process seemed sufficient. The issue must have stemmed from the kiln. Inspecting two kilns closely, he frowned. "What materials are these kilns made of?" he asked.

Harihar replied hesitantly. "To my knowledge, they are made of fine-quality firebricks, clay, and straw. However, I’ve heard of superior kilns reinforced with steel for added durability. These are typically reserved for privileged classes. If Your Highness permits, we could replace our kilns with those, which might prevent such accidents."

Aditya turned to Ashutosh. "Secure the annual kiln-supplying contract. No matter the cost, make it happen."

Ashutosh bowed. "As you command, Your Highness."

Aditya exhaled, his mind set on improving the facility’s safety. "Summon all skilled artisans to the office immediately. I have a proposal to make. And ensure Govind joins us as well."

Ashutosh nodded and left to carry out the orders.

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//A/N: Thanks to KB1387 for your warm support by donating 1 new GT ticket. Your immense support is deeply appreciated. :)