BULLETPROOF JACKETS

STAR WIRE (INDIA) LIMITED has designed bulletproof jackets (BPJ) to meet the requirements of the Defence Forces, Paramilitary Forces and Dignitaries. These are modular and meet all requirements ofArmed Forces and other Security Forces deployed in high threat operational environments.





Star Wire (India) Ltd (SWIL) is the leading manufacturer of Bullet Proof (BP)/ Armour Steel in the private sector in India. The company is a registered manufacturer of armour steel with the Director General, Quality Assurance, Ministry of Defence, Government of India. It manufactures:

  • 5 mm & 6.5 + .05 mm rolling tolerance steel in 500 BHN for NIJ Level III against 7.62x39 mm AK 47 & 7.62x51 mm NATO Ball respectively.

  • 4.2 mm & 5.5 mm in 600 BHN for NIJ Level III against 7.62x39 mm AK 47 & 7.62x51 mm NATO Ball respectively

  • 12–14 mm in 500 BHN for NIJ Level IV against .30-06 M2 Armor Piercing (AP), 7.62x51 mm AP, 7.62x54 mm AP NATO Ball

  • 5 mm in 650 BHN for NIJ Level III against 7.62x39 mm (HSC) AK 47 & 7.62x51 mm

Model SWIL - 01


SWIL's discreet armour waistcoat for important dignitaries like VIPs and their body guards. It is fabricated with high quality ballistic grade Aramid/PE fabric to provide complete protection to the torso from the front, flanks and the back of an individual wearing the jacket.

  • Protection: Front, flanks and back from bullet velocity up to 425m/sec from a range of 5 meters
  • Weapon Types: 0.22 Long Rifle, 0.32 Revolver/Pistol 0.38,9mm Parabellum, Carbine/Sten Gun, and 0.44 Magnum
  • Weight: 2.25 to 2.50 kg approx.
  • Threat Perception: NIJ Level II &IIIA
  • Available Colour: White, Black, Blue
  • Features: Washable outer cover design allows unhindered arm movement, breathable inner lining with sweat absorption provision to insert additional composite armour inserts

Model SWIL - 02


Model SWIL02 is an enhanced light-weight jacket which has been designed by SWILto provide light-weight standalone solution for soldiers. It is tailored with non-ballistic fabric. The jacket without HAP provides protection to the side flanks, collar, neck and groin, etc. against fragments and splinters of hand grenade and defeat fire assault of relevant weapons from the front and back.

Composition of the jacket:

  • The jacket consists of outer carrier, removable SAP and two HAP made of high performance composite material (with ultra modern high performance bulletproof steel plate) to provide protection against all small arms NATO weapons. It also provides optimum mobility.
  • It has high quality hooks and loop fasteners.
  • It has three external pockets to house two magazines and a grenade. The size of the pocket is as per the requirement.
  • An additional belt is provided around the waist to secure the jacket tightly.
  • The outer cover is washable.
  • SAP and HAP are removable from the outer carrier.
  • The material has high tenacity, and is heavy duty, water resistant and fire resistant
Cartridge Weapon Distance Velocity Bullet weight
9x19mm Submachine gun 5 mtrs 430+_15 m/s 7.4 to 8.2 gms
7.62x51 mm NATO Ball 7.62 mm SLR 10 mtrs 838+_15 m/s 9.4 to 9.6 gms
7.62x39 mm MS core AK series 10 mtrs 715+_15 m/s 7.45 to 8.05 gms
7.62x39 mm HS core AK series 10 mtrs 635+_15 m/s 7.45 to 8.05 gms
5.56x45 mm Ball MK -1 INSAS series 10 mtrs 890+_15 m/s 3.5 gms to 4 gms

Note: HAP can take 03 burst fire of 03 shots each. Shot to Shot and Edge to Shot distance is reduced to 20 mm as against 51 mm laid down testing parameter.

Model SWIL - 03


This model has been designed for Armed Forces and other Security Forces deployed in high threat operational environments. It has non-ballistic fabric harness reinforced with SAP tailored with Aramid/PE and composite Hard Armour Plates (HAP).

Composition of the jacket:

  • The harness holds the weight of SAP/HAP. Its fabric is rip stop coated with polyurethane / neoprene material
  • The jacket has arrangements to carry:
    • Three AK-47 rifle magazines (size: 22.7 cm x 6.6 cm x 2.3 cm)
    • Two hand grenades (size: 10.1 cm and diameter of 7 cm
    • One hand-held radio (easily accessible) (size: 12.7 cm x 6 cm x 4.4 cm)
    • Two 7.62mm light machine gun magazines (size: 21.7 cm x 7.7 cm x 2.5cm)
  • The jacket covers a protected total area of minimum 4800 sq cms, including the neck, collar and groin

Soft Armour Panel (SAP):

The front, back and sides of the bulletproof jacket consists of SAP made of PE/Aramid (sides SAP will be part of the front SAP), including neck and collar pad and groin pad as mentioned below.

Neck and Collar Pad/Pads:

It is detachable (one or two pieces design), specially contoured to fit and provide ballistic protection all around the neck with width not exceeding more than 80mm. The protection (except trauma attenuation) conforms to that of the front and back

Groin Pad:

It is detachable, protects the groin in continuation with the front SAP and does not impede the movement of a soldier. HAPs are needs-based add-on inserts to protect the front, sides, back, throat and groin.

Weight and Area Aspects:

Area (minimum) Weight Protection from
Front 0.1000 M² 1.90 kg AK 47 Hard Steel Core and Mild Steel Core, 7.62 x 51 SLR and 9mm KF
Back 0.1000 M² 1.90 kg AK 47 Mild Steel Core, 7.62 x 51 SLR and 9mm KF.
Sides 0.0750 M² 0.90 kg AK 47 Hard Steel Core and Mild Steel Core, 7.62 x 51 SLR and 9mm KF
Throat (Detachable) 0.0270 M² 0.30 kg AK 47 Mild Steel Core, 7.62 x 51 SLR and 9mm KF.
Groin (Detachable) 0.0375 M² 0.45 kg AK 47 Mild Steel Core, 7.62 x 51 SLR and 9mm KF.
Total 0.3395 M² 5.35 kg
Soft Armour Panel 0.4800 M² 4.25 kg
Harness 0.8 kg
Weight of Complete BPJ 10.4 kg
BFS 25mm (Max)

Note: HAP can take 03 burst fire of 03 shots each. Shot to Shot and Edge to Shot distance is reduced to 20 mm as against 51 mm laid down testing parameter

Model SWIL - 04


This model has been designed to meet the requirements and specifications of Para Military and State Police Forces. The Jackets/Vests have been tailored with non-ballistic fabric reinforced with SAP tailored with Aramid/PE and Composite Hard Armour Plates (HAP).

Composition of the jacket:

  • SAP front, back and sides (sides SAP is part of the front SAP) including neck and collar pad and groin pad.
  • The neck and collar pad is detachable (one or two pieces design), specially contoured to fit and provide ballistic protection all around the neck.
  • The groin pad is detachable. It protects the groin in continuation with the front SAP and does not impede the movement of a soldier.
  • It covers about 500 sq cms protected area.
  • HAPs are needs-based add-on inserts to protect the front, sides, back, throat and groin
Cartridge Weapon Distance Velocity Bullet weight
9x19mm Submachine gun 5 mtrs 430+_15 m/s 7.4 to 8.2 gms
7.62x51 mm NATO Ball 7.62 mm SLR 10 mtrs 838+_15 m/s 9.4 to 9.6 gms
7.62x39 mm MS core AK series 10 mtrs 715+_15 m/s 7.45 to 8.05 gms
7.62x39 mm HS core AK series 10 mtrs 635+_15 m/s 7.45 to 8.05 gms
5.56x45 mm Ball MK -1 INSAS series 10 mtrs 890+_15 m/s 3.5 gms to 4 gms

Note: HAP can take 03 burst fire of 03 shots each. Shot to Shot and Edge to Shot distance is reduced to 20 mm as against 51 mm laid down testing parameter.

Model SWIL - 05


Model SWIL 05 is a light-weight buoyant bulletproof jacket, also known as floatation jacket. It has been designed by SWIL for personnel deployed for security duties at sea and ashore. This floatation jacket is light-weight and tailored with non-ballistic fabric to withstand conditions in hot, humid climate areas or at sea and in close proximity to water. It is modular, adaptable for multiple threat levels and provides protection to vital areas of the body. It is comfortable to wear and does not restrict the soldier from performing his duties. It is waterproof and positively buoyant to keep the wearer, with the jacket donned, afloat in water.

Composition of the jacket:

  • The jacket consists of outer carrier, removable SAP and two HAP made of high performance composite material (with high performance BP Steel Plate). It has lifesaving floating capability and also consists of a removable inflatable stole located underneath the level III armour pack to protect the wearer from bullet or fragment threats.
  • It has high quality hooks and loop fasteners, and offers sufficient ruggedness to withstand rough handling in operational environment.
  • It is capable of being donned/removed by the wearer without need of external assistance.
  • The outer carrier has high tenacity, and is heavy duty, water resistant and fire resistant.
  • Automatic and manual inflation facility is available with inflatable stole.
  • The gas inflatable bladder is fitted with an automatic trigger which deploys within seconds in water.
  • The armour vest automatically expands around the bladder when activated to provide continuous protection.
  • The jacket's fully upgraded configuration is buoyant when donned by a wearer weighing not more than 80 kgs, fully kitted with equipment/gear of not more than 12 kgs weight. The jacket can keep the wearer afloat, with at least the bottom of the neck clearly above the water, without requiring assistance from the wearer and can float in sea water over a duration of approximately 8 hours.

Weight and Size:


The BPJ provides two different sizes (Medium and Large), conforming to the Indian physique, as follows:-

S.No Size Chest Size SAP HAP Weight (Minimum area) HAP Weight (minimum dimension per plate) Weight with both HAP placed on the Jackets (Upgrade II version not to exceed)
a. Medium 95 cm – 105 cm 5000 sq cm 25 cm x 30 cm 6.0 kg
b. Large 106 cm – 115 cm 5500 sq cm 25 cm x 30 cm 6.3 kg

Model SWIL - 06


Model SWIL 06 is a light-weight bulletproof jackets/vest tailored with non-ballistic fabric and reinforced with SAP of Aramid/PE/UHMPE and HAP made of PE/UHMPE. The jacket without HAP provides front-to-back wrap around ballistic protection, including the collar, neck and groin, etc., against fragments and splinters of hand grenade and defeat fire assault of relevant weapons.

Composition of the jacket:

  • The jacket consists of an outer carrier, removable SAP and two HAP made of high performance composite material (with thin high performance steel plate) to provide protection against all small arms NATO weapons. It also provides optimum mobility to the wearer.
  • It has high quality hooks and loop fasteners.
  • It has two external pockets to house two magazines and a grenade
  • An additional belt is provided around the waist to secure the jacket.
  • The outer cover is washable.
  • The material has high tenacity, and is heavy duty, water resistant and fire resistant
Cartridge Weapon Distance Velocity
9x19mm Submachine gun 5 mtrs 430+_15 m/s
7.62x51 mm NATO Ball 7.62 mm SLR 10 mtrs 838+_15 m/s
7.62x39 mm MS core AK series 10 mtrs 715+_15 m/s

Weight:

  • Soft Armour Jacket – approx. 2.5 to 3 kg with collar and groin protection
  • Polyethylene HAP – approx. 3 kg (2x Inserts of size 10”x12”)
  • Total weight – 5.5 kg to 6 kg approx








The Company has the following certifications:

  • ISO 9001 – Quality Sys approval by DNV (2002)
  • ISO/TS16949 – Quality Sys approval for Automotive Products application for DNV 2002
  • ISO 14001 – Certificate for Environment (2005)
  • OHSAS 18001 – Sys Certificate for Safety & Health(2005)
  • NABL – Approved laboratory by Government of India for certification
  • DGQA – Registered & approved for manufacturing of Armour for specifications- CAQ(M) 47
  • HP White Lab Inc USA – Test approved