Aluminium Foil & Sheet Project Report

ALUMINIUM FOIL & SHEET
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This project report has been prepared on the basis of information available with our Institute and Project Coordinators. The intention here is to provide preliminary information to the prospective entrepreneur. Prior to making a firm decision for investment in the project the entrepreneur must verify the various feasibility aspects together along with the addresses for the procurement of plant & machinery and raw materials independently. The informations supplied in this report is obtained from the reliable sources but it is not guaranteed, and the money once paid will not be refunded back in any case. Claims for incomprehensiveness of the project report will not be entertained and no legal action in this regard would be entertained in any case (Subject to Rajkot Jurisdiction only). Any matter relating to our standard points covered in the report may be modified with in 5 days time only from the date of delivery.
INDIAN PROJECT RESEARCH INSTITUTE | Project Coordinator : Mr. Abhishek
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ALUMINIUM INGOTS FROM ALUMINIUM SCRAP

[EDPR/0966] (J.C.9601) C O T E N T S
1. 2. 3. 4. 5. 6.
INTRODUCTION PROPERTIES OF ALUMINIUM USES AND APPLICATIONS B.I.S. SPECIFICATIONS MARKET SURVEY MANUFACTURER/SUPPLIER/EXPORTER OF ALUMINIUM ALLOY INGOTS 7. MANUFACTURING PROCESS 8. PROCESS FLOW SHEET 9. PRINCIPLES OF PLANT LAYOUT 10. PLANT LOCATION FACTORS 11. EXPLANATION OF TERMS USED IN THE PROJECT REPORT 12. SUPPLIERS OF PLANT & MACHINERIES 13. SUPPLIERS OF RAW MATERIALS APPENDIX - A 1. COST OF PLANT ECONOMICS 2. LAND & BUILDING 3. PLANT AND MACHINERY 4. FIXED CAPITAL INVESTMENT 5. RAW MATERIAL 6. SALARY AND WAGES 7. UTILITIES AND OVERHEADS 8. TOTAL WORKING CAPITAL 9. COST OF PRODUCTION 10. PROFITABILITY ANALYSIS 11. BREAK EVEN POINT 12. RESOURCES OF FINANCE
3 5 7 10 11 22 32 36 37 42 45 47 68
A 1 A 2 A 3 A 5 A 6 A 7 A 8 A 9 A11 A12 A13 A14
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INTRODUCTION
Aluminium is a metal with high strength-to-weight ratio, better formability, high ductility, anti-corrosive properties, with thermal and electrical conductivity. Because of these unique combination of properties, aluminium(including its alloys) has substantially replaced a number of traditional materials from their established uses e.g. steel, copper, lead and zinc among metals and glass. Wood and paper among non-metals. Aluminium is crucial for expansion of power availability and electrification programme. It has a significant role to play in saving energy in transportation sector, thus help reducing the consumption petroleum products. ALUMINIUM IN INDIAN ECONOMY:Aluminium plays a key role in the progress of industrial development in India because it serves as basic input for a number of industries apart from its use as a strafesic metal. Progressing a long way since early fifties, with a meager production capacity of 5000 TPA it has reached a level of 362000 tonnes by 1982-83. With the coming on stream of National Aluminium Company (NALCO) project by 1987-88 asa major producer in the country, the industry will attain a quantum jump to the level of 580000 TPA. Thus, there will be a sea change in the Indian aluminium scene. From a net importer of aluminium, India will emerge as a country with surplus aluminium for some years to come until the rising demand overtakes availability once again. It is however, felt that the growth rate of demand could have been higher but for the following factors. a. Restricted indigenous availability of commercial grade aluminium inhibitting the application of aluminium in place of other conventinal materials in the transport building engineering and other sectors. b. Insufficient development. R & D efforts for new product application and
c. Inadequate market research and market development to diversify into new areas.
Development of high strength alloys good formability, improved casting and welding techniques have opened up wide areas of application of aluminium in the machinery and equipment sector. 3|P age
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Another important area is the utensils, household appliances and consumer durables. Aluminium due to its conductivity, light weight, durability and non toxicity constitutes the most fuel efficient and hence the ideal material for kitchenwares. Widespread usuage of aluminium utensils is, therefore, necessary in the larger context of fuel saving. With the development of high strength alloys, and attractive utensils and for increasing consumption of aluminium in this sector. The country is now entering a phase when ensuring adequate availability of alumina will not be a problem for some years to come. The emphasis has to shift to developing the new application areas.
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PROPERTIES OF ALUMINIUM
Aluminium is a silvery and crystalline sold metal. It is a light metal having no melting temperature and can be easily casted aluminium forms a protective coating of Al2O3 about 50 A which, makes it highly resistant to ordinary corrosion. Aluminium is attached by concentrate and dilute solutions of HCl, hot concentration H2SO4, and prechloric acid, aluminium is pretoxic and is non-combustible except in powder form. Pure aluminium is a relatively poor casting mateerial. It's castings are actually produced from alloys. The casting alloys are those having properties peculiary suited for casting purposes. For these alloys two types of properties must be considered, the casing properties, those characteristics of alloy which determine the ease or difficulty of producing acceptable castings, and the engineering properties. The aluminium-base alloys may in general be characterised as eutectic systems, containing intermediate compounds or elements as the excess phase, because of the relatively low solubilities of most of the alloying elements in aluminium and complexity of the alloys that are produced, any one aluminium-base alloys may contain several metallic phases, which sometimes are quite complex in composition. The principal alloying elements in aluminium-base casting alloys are copper, silicon, magnesium, zinc, chromium, manganese, tin and titanium. Improvement in strength and hardness and response to heat treatment are obtained with proper percentage of copper magnesium, zinc or certain combination of magnesium and silicon in aluminium alloys. Excessive percentages of these elements, however, result in complete lots of ductility and toughness. The Aluminium metal processed in various forms has been found to be suitable for a variety of domestic and industrial uses. The reasons of its usage in wide range of shapes and sizes can be found in physical and chemical properties of this metal. The most significant properties of this material: a) Amenability to thermal and mechanical treatments or malleability, b) Lower specific gravity, c) Good conducting properties-thermal and electrical, 5|P age
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d) Can be alloyed to obtain desired improvements in strength, e) Resistant to chemical attacks It has been possible to process this metal in various forms to obtain the products with the requisite properties Thus, although the earlier usage of Aluminium was restricted to pots and pans, Aluminium is now being used for a variety of uses like in aircraft, electronics, roofing, packaging, building industry, etc.
ALUMINIUM FOIL:The Foil is a continuous web of aluminium metal rolled to thickness ranging from 0.005 mm to a maximum of 0.15 mm. Foil is available in many forms, Le., hard, soft (annealed), lubricated, non-lubricated plain, coated, coloured, printed, embossed and laminated to a variety of paper and synthetic films. Aluminium foil has significant properties as given below: a) Good thermal and electrical conductivity, b) Good formability, c) Impermeability and non-absorptivity to water, grease, oil & light; d) Odourless and tasteless, e) Good adhesion to a variety of compounds, f) Excellent printability, g) Resistance to oxidation and chemical attacks Owing to these properties, aluminium foil is preferred to other packaging materials as flexible materials cannot match these characteristics of aluminium foil.
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USES AND APPLICATIONS
Aluminium is the most widely used non-ferrous metal. Global production of aluminium in 2005 was 31.9 million tonnes. It exceeded that of any other metal except iron (837.5 million tonnes). Forecast for 2012 is 4245 million tons, driven by rising Chinese output. Aluminium is almost always alloyed, which markedly improves it mechanical properties, especially when tempered. For example, the common aluminium foils and beverage cans are alloys of 92% to 99% aluminium. The main alloying agents are copper, zinc, magnesium, manganese, and silicon (e.g., duralumin) and the levels of these other metals are in the range of a few percent by weight. Some of the many uses for aluminium metal are in: Transportation (automobiles, aircraft, trucks, railway cars, marine vessels, bicycles, etc.) as sheet, tube, castings, etc. Packaging (cans, foil, etc.) Construction (windows, doors, siding, building wire, etc.) A wide range of household items, from cooking utensils to baseball bats, watches. Street lighting poles, sailing ship masts, walking poles, etc. Outer shells of consumer electronics, also cases for equipment e.g. photographic equipment. Electrical transmission lines for power distribution MKM steel and Alnico magnets Super purity aluminium (SPA, 99.980% to 99.999% Al), used in electronics and CDs. Heat sinks for electronic appliances such as transistors and CPUs. Substrate material of metal-core copper clad laminates used in high brightness LED lighting. Powdered aluminium is used in paint, and in pyrotechnics such as solid rocket fuels. Aluminium can be reacted with hydrochloric acid or with sodium hydroxide to prodce hydrogen gas.
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A variety of countries, including France, Italy, Poland, Finland, Romania, Israel, and the former Yugoslavia, have issued coins struck in aluminium or aluminium-copper alloys. Some guitar models sports aluminium diamond plates on the surface of the instruments, usually either chrome or black. The per capita consumption of aluminium in India is about 0.4 Kg as compared to the average of about 4 Kgs. in the world, about 18 kgs. Japan and 27 Kgs. of USA. This indicates an ample scope for promotion of the use of aluminium in the country in the various sectors of our economy. The pattern of consumption relects the priorities of a country consistent with its resources and stage of development. Where as in India, a developing country, while over 50 % of the consumption is accounted for by electrical sector reflecting compulsions of building up the indusirial infra-structure for power generation and distribution, in USA, containers and packaging is the largest sector indicating the emphasis for proper packaging of consumer goods. In Japan, the highest consumption to aluminium is in the building and construction sector because of the need for light buildings. The foil is used for packaging of many products, some of which are given below: Pharmaceutical tablets Bulk & unitized packing of tea and coffee Prepared meals Bakery products Frozen meat, fish Milk bottle caps Wine Lube Oil, greases Powdered milk Confectionery Biscuits Photographic film Gift wraps Household wraps Butter, margarine Cigarettes
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Product Range Light Gauge Foil: 7, 8, 9 and 12 micron Tagger Foil/ Container Foil: 50-100% micron Pharma Foil : Unrprinted and Printed (5 colours ) 25, 30 and 40 micron poly laminated foil Cigarette Foil: Plain and Coated
Medium Gauge Foil: 15-50 micron TRIPLE LAMINATE FOR PACKAING FOUR PLY PACKAGING
Heavy Guage Foil: 60-200 micron Web Stock Foil: 15, 20, 30 and 40 micron Blister Pack Foil : Unrprinted and Printed (5 colours ) 20 , 25 and 30 micron Lidding Foil: Unrprinted and printed 30-38 and 40 microns
HOUSE FOIL
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B.I.S. SPECIFICATIONS
IS: 617-1975 Aluminium and aluminium alloy ingots castings for gerierd engineering purposes (IIIrd revision with mould metals). IS: 20-1977 Cast aluminium alloys for manufacture of utensils (IIIrd revision). IS: 2066-1962 - Coading and classification for non ferrous scrap metal & residues. Section I of this standard deals with non ferrous scrap metal e.g. aluminium brass bronze copper lead tin nickle & zinc section - II deals with metallurgical residues e.g. slags, skimming drosses etc. An appendix specifies conditions of slags. IS: 8970-1991 revision) IS 7161:1973 Aluminium foil laminates for packaging (first
Vegetable parchment orgrease proof Aluminium foil laminate for wrapping butter
paper
IS 10257:1982 - Aluminium foil stock Above Specifications may be obtained from Bureau of Indian Standards, 9, B.S. Zafar Marg, New Delhi - 110 002. NOTE :- The use of the ISI Certification Mark is governed by the provisions of the Indian Standards Institution (Certification Marks) Act and the Rules and Regulations made thereunder. The ISI Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well-defined system of inspection, testing and quality control which is devised and supervised by ISI and operated by the producer. ISI marked products are also continuously checked by ISI for conformity to that standard as a further safeguard. Details of conditions under which a licence for the use of the ISI Certification Mark may be granted to manufacturers or processors, may be obtained from the Indian Standards Institution.
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MARKET SURVEY
Indian Aluminium Industry, though of comparatively origin, has progressed very fast and at present it ranks first among nonferrous metals, both in production and in consumption. The history of aluminium industry in India started in 1929 with the manufacture of aluminium utensils from imported aluminium sheets and coils. India entered the field of aluminium smelting in 1943 when a small plant was set up by the Indian Aluminium Company (INDAL) at Alupuram in Keral. Excepting electricity, the plant operation was based on imported raw materials. The production during the year of inception was only 1292 tons. West Bengal was the state for the setting-up of second Aluminium smelter in 1944 by Aluminium Corporation of India (ALUCOIN) at Jaykay Nagar, Asnsol, having a capacity of 9000 TPA. It was only after 1960 that aluminium industry in India made a rapid growth. At present there are five primary aluminium producing companies in the country. Two of these namely Bharat Aluminium Company (Balco) and National Aluminium Company (MALCO) are in private sector. The aluminium corporation in India (ALUCOIN) started initially as private sector company, is lying closed since 1973 but its fabrication facilities have since been taken by BALCO. It was only after 1960 that aluminium industry in India made a rapid growth. At present there are five primary aluminium producing companies in the country. Two of these namely Bharat Aluminium Company (Balco) and National Aluminium Company (MALCO) are in private sector. The aluminium corporation in India (ALUCOIN) started initially as private sector company, is lying closed since 1973 but its fabrication facilities have since been taken by BALCO. The first public sector plant BALCO at Korba in MP came in production in the year 1975 with its smelter capacity of 2500 TPA. At present its production capacity is 100000 TPA. NALCO, which is the latest and now the largest integrated plant, is expected to commence its production in 1987 at Angul in Orissa and will have metal production capacity of 21800 TPA.
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LICENSED AND INSTALLED CAPACITY OF PRIMARY ALUMINIUM IN INDIA
India is considered the fifth largest producer of aluminium in the world, following Australia, Guinea, Brazil and Jamaica. It has huge reserves of high-grade bauxite. It is estimated at about 3037 million tonnes for all categories of bauxite (proved, probable and possible). With the present level of consumption of aluminum (assuming 1.2 million tonnes of aluminium production with 7 million tonnes of bauxite), the identified reserves would have an estimated life of over 350 years. India's reserves are estimated to be 7.5 per cent of the total deposits and installed capacity is about 3 per cent of the world. In terms of demand and supply, the situation is not only selfsufficient, but it also has export potential on a competitive basis. India's annual export of aluminium is about 82,000 tonnes. The global consumption of aluminium is estimated to grow at 3 to 4per cent from 2000 to 2007. This provides a market signal for potential growth of Indian aluminium industry and export of both alumina and aluminium. About a decade back, the primary Indian aluminium producers were BALCO, NALCO, INDAL, HINDALCO and MALCO. Of the five, two (BALCO and NALCO) were in the public sector while the other three were in the private sector. MALCO was 'sick' and on the path to closure. Public sector enterprises then enjoyed preferential treatment in the form of explicit protectionism. Therefore, the cost of production of BALCO was benchmarking the selling prices in the domestic market. With the inception of NALCO in 1981, the production pattern shifted in favour of the public sector. This happened as BALCO with a capacity of 100,000 tonnes per annum and NALCO with an installed capacity 230000 12 | P a g e
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TPA, boosted the output share of primary aluminium from the public sector. The domestic market was dominated primarily by the public sector though prior to this, HINDALCO and INDAL were the main players. The shift from the private to the public sector and again from the public sector back to the private sector has been a notable change in Indian industry. Presently, of the 714,000 TPA installed capacity in the country for production of primary aluminium, the public sector commands 330,000 TPA (49.21 per cent) and the private sector accounts for 384,000 TPA (53.78per cent.) This represents a gradual but deterministic shift in the production pattern. With BALCO'S disinvestments on the cards, the share of the private sector will increase at the commensurate rate (i.e. expected to be 67.8 per cent in private sector). Earlier, HINDALCO and BALCO were the trendsetters for prices in the country. Earlier, domestic sale of aluminium had administrative prices along with distribution controls. With liberalisation, the prime strategies are the joint venture investments, technology acquisition/offers, international marketing tie-ups, buy back arrangements and subcontracting, technical, managerial and marketing expertise. As a part of reform, several policy changes have been enunciated to ensure hassle free entry of private investment. Similarly, as part of moving towards privatisation, the government is withdrawing its presence from as many areas as possible, through closure and sale of equity or disinvestments. Prospects for the aluminium industry seem to be bright as aluminium is being used increasingly in energy efficient vehicles. For instance, the space shuttle, the HUMMER vehicle, and the Ferrari 360 Modena all are made of high performance aluminium. Material automakers are increasingly choosing to improve fuel economy, reduce emission and enhance vehicle performance. Aluminum is likely to surpass plastic in the coming years as it will be used more in light vehicles. The recent announcement from the Ford Motor Company to improve fuel economy in its SUVs is another signal that aluminium usage will increase even faster. Automakers are responding to consumer demands for cleaner, more efficient and safer cars and trucks. Hybrid-electric technologies get much attention, but cost and complexity are preventing their immediate, widespread use. It is a recognised fact that aggressive weight reduction is the best way to improve fuel economy, emissions and performance. For these reasons, 13 | P a g e
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as well as improved corrosion resistance and recyclability, automakers are more and more turning to lightweight, high-strength aluminium. NALCO and BALCO have been identified for disinvestments. The government has decided to disinvest up to 51 per cent of equity held in BALCO through sale to strategic partners. NALCO has authorised capital worth Rs 1300 crore and Rs 644.31 crore paid up capital and loan of 980 million of Euro-dollar. The government's stake in NALCO is about 87 per cent, which may be diluted further as it has set a target of disinvesting upto Rs 10,000 crore through the sale of equity held by the government in PSUs. As a result of the process of liberalisation of trade in aluminium, India has emerged as a net exporter of aluminium, on competitive terms. Government monopoly, in terms of aluminium production, removal of price and distribution control over aluminium, has been diluted in favour of private sector. The ownership pattern in private sector has undergone changes. With the takeover of INDAL by the HINDALCO, it has emerged as the major producer of aluminium in the country. It could be safe to conclude that Indian aluminium industry is a success story of the reforms, liberalisation, globalisation and privatisation drive in India. Demand prospects bright for aluminium Domestic aluminium producers will be relieved, as aluminium prices ended the year on a firm note, after falling halfway through the year. On Wednesday, Hindalco Industries Ltd touched a new 12-month high of Rs. 243 before closing a bit lower. The rise in its share price may have been prompted either by expectations of better performance in its domestic operations or even at its Canadian subsidiary Novelis Inc. Domestic aluminium producers will be relieved, as aluminium prices ended the year on a firm note, after falling halfway through the year. Aluminium prices on the London Metal Exchange (LME) have risen by just 7% to $2,404 (Rs. 1,08,420) a tonne, compared with the year's opening level. That is a meagre increase, especially when you consider that its base metal cousin, copper, did extremely well, rising by about 26% in the same period. But aluminium has done well since June, when it fell to a low of about $1,850 a tonne.
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Demand for aluminium was quite solid during the year, as the world economy overall was in better shape, despite China's efforts to cool economic growth and shivers caused by Europe's economic worries. Alcoa Inc. estimated aluminium production in 2010 to increase by 13%. Global primary aluminium production rose by 3.5% in 2010, till November, compared with the year-ago period, based on data from the International Aluminium Institute(IAI). Despite a 3.5% increase in production, LME inventories fell from 4.6 million tonnes (mt) in January 2010 to 4.3 mt. Physical inventories of primary aluminium with companies, measured by the IAI, have risen marginally, by about 5% to 1.3 mt. Alcoa forecasts world aluminium consumption to increase from 39 mt in 2010 to 73 mt in 10 years, achieving a compounded annual growth rate of 6.5%. In the April-November period, India's aluminium output rose by 8%, chiefly due to ramp-up of production at Vedanta Aluminium Ltd's Jharsuguda smelter, according to the ministry of mines statistics. Domestic players are expanding capacity, anticipating rising demand which cannot be catered to by existing capacities. Most global players, too, are expanding capacities. Despite an increase in supply, Alcoa expects that the market will remain tight in the next decade, due to demand outstripping supply. Indian firms are expanding existing capacities and also setting up new plants. Some have come up in 2010, but the bigger plants will come up in the next few years. India's demand is expected to grow faster than global demand, as its industrial growth sustains momentum, especially the major users of aluminium industries such as real estate, automobiles and engineering. Aluminium prices are influenced by demand from financial investors and from actual users of the metal. The current rush for commodities provides a firm floor for prices, but it could quickly disappear causing prices to wobble. This was visible in June, as fears surrounding Europe spooked investors. The inventory overhang in aluminium too continues but, having weathered it for a year, it does not seem to be worrying investors. UC Rusal, a large aluminium producer, believes that most LME inventories are covered by financial transactions and will not come into the market before mid-2012. Indian aluminium producers are in a good position, with aluminium prices already up about 30% since the lows of June. But it has 15 | P a g e
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underperformed compared with commodities such as copper. The question is if that will change in 2012, for that will determine how much of an upside there is for investors in aluminium stocks. As of now, there is little to suggest a runaway movement in aluminium prices. In 2011, Indian firms will benefit more from their capacity additions, which will contribute to a better financial performance. Hindalco Industries Limited Q3 FY 2007-2008 Results Hindalco Industries Ltd., the flagship company of the Aditya Birla Group, today announced its unaudited financial results for the quarter ended December 31, 2007. Net sales and operating revenues stood at Rs.4,531.7 crores as compared to Rs.4,656.2 crores in the corresponding period in FY 07. The net profit for the quarter is Rs.542.7 crores vis-avis Rs. 643.9 crores in the corresponding period of previous year. These results need to be viewed in the context of macroeconomic parameters as these adversely impacted the quarter under review. Domestic Aluminium ingot prices are down by around 20% due to the rupee appreciation. A 10% lower aluminium LME, 41% lower Tc/Rc in copper and soaring international crude prices have exerted considerable pressure on margins. This was mitigated to some extent by sweating capacities, improving realization through an enriched product/market mix, optimizing efficiency levels and producing highest ever aluminium metal in a quarter. Of the total revenues of Rs. 4,531.7crores, the aluminium business contributed Rs. 1,729 crores. Aluminum metal sales volume rose by 12% along with higher proportion of value added products. The profit Rs.578.9 crores quarter in the rising rupee and before interest and tax for aluminium business was at as against Rs. 755.5 crores in the corresponding earlier year, as stated earlier, mainly due to the fall in global alumina realization.
In the copper business, revenues stood at Rs.2806.2 crores driven by higher sales volumes and an enriched product mix. The profit before interest and tax was Rs. 94 crores against Rs. 159.5 crores in the corresponding quarter last year. As mentioned earlier, a 41% lower TcRc and lower duty differential on imports constrained the copper business.The effect of 16 | P a g e
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these were partially offset by improvement in the market mix with higher sales in domestic market, lower grid power usage on improved captive power availability, energy consumption and better realization from by-product sale. Moreover, steep appreciation of Indian Rupee against US Dollar adversely impacted segment results of Copper by an estimated Rs.54 crores for the quarter under review as a result of restatement of net foreign currency exposures as on December 31, 2007. For the corresponding quarter of the previous year, this had an estimated favourable impact of Rs.86 crores on such results. Consequently, the Copper segment results for the quarter under review are lower than the corresponding quarter of the previous year by an estimated noncash impact of Rs.140 crores on this account. Operational review All the aluminium plants operated at consistently high capacity utilisation. Brownfield expansions have resulted in increasing metal production by 9%. The downstream assets purchased in the last two years are fully utilized, in addition to consistent production from other plants. Production of value added products (VAP) viz. Rolled products and Extrusions production extended by 6 per cent and 10 per cent respectively. Alumina production was marginally less than last year predominantly due to the hooking of existing alumina refinery with expanded facility at Muri. Copper Copper cathodes and CC rods production increased by 7% and 38 % respectively on YoY basis on the back of the ramp up of the copper-III smelter and consistent production from smelter-I. The operations at copper smelter -II continue to be suspended. Expansion projects Muri The expansion of the Muri Alumina refinery from 110,000 tpa to 450,000 tpa is under commissioning in a phased manner. The entire steam and power requirement is being met by the new captive power plant. The production from the expanded facility is expected to be stepped up progressively in Q4FY08. Hirakud
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Phase II of the expansion of the smelting capacity from 100,000 tpa to 143,000 tpa is on track. The scaling up of the power generation capacity from 267.5MW to 367.5MW will go on stream by the fourth quarter of this fiscal.
Belgaum The allotment of the lease for bauxite mines for expanding the alumina refinery capacity at Belgaum, Karnataka from 350 ktpa to 650 ktpa is awaited.
Aditya Aluminium Aditya Aluminium, the integrated aluminium project, encompassing 1-1.5 million tpa alumina refinery, 260,000-325,000 tpa aluminium smelter and 750 MW captive power plant is progressing as planned. The major portion of the total land required for the project has been acquired. Environmental clearances have been obtained for Smelter, the Captive Power Plant (CPP) and the refinery. Joint venture Company is formed for the coal block. The water drawal agreement is also finalized. Construction power already in place, the regulatory clearances obtained for transmission lines for operation power. The Smelter is expected to be commissioned by March, 2011 and the refinery by May, 2011. Mahan The Mahan Aluminum project with a smelter capacity of 325 ktpa and CPP of 750 MW is on schedule. The land acquisition for the project is underway. The Company has been allotted a coal block in a JV with the Essar group for the coal requirement of the CPP. Preliminary Environmental clearances have been obtained. The power connectivity for commencing construction has been approved. The Water resource department has provided the necessary facilities as well. The production of coal is likely to start by Oct'09. The Smelter is expected to roll on by September 2012. Latehar
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For the Latehar project with a smelter capacity of 325 ktpa and CPP of 750 MW, Tubed Coal mine has been allocated jointly with Tata Power. Preliminary Environmental clearances have been obtained. Land acquisition is in progress. Power for construction activity is sanctioned. The expected date of commissioning is September 2013. Utkal Work on Utkal Alumna's 1.5 MTPA Alumina Refinery is underway. The Company has acquired the land for the plant and facilities. Mining activities will start by March 2009. The civil works for Alumina refinery and CPP is in progress. The commissioning of the Plant is expected by March 2010. Hindalco Almex Aerospace Limited This project for manufacture of high strength aluminium alloys for applications in the aerospace, sporting goods and surface transport industries is on target. Key equipment has begun to arrive at site for installation. Industry outlook Global primary aluminium consumption has witnessed a strong growth of 10 % from April through December 2007. US production levels have seen a high growth but demand from residential construction market and transport markets continues to remain weak. Demand from Western Europe has been relatively stronger due to firm transport and engineering markets. China is the strongest driver of the demand as the metal grew at 34.7%, in this period, with demand from the power, transport and construction markets bolstering growth. Copper The bullish run on the copper prices has been halted due to global economic and financial woes and the trend is likely to be downward. With many major smelters announcing annual maintenance shutdown during April -June'07, the availability of concentrates would improve, resulting in a higher spot TCRC. Company outlook Going forward, higher volumes from asset sweating of existing plants, the brownfield expansions and continued cost focus together with effective working capital management to maximise free cash flow 19 | P a g e
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will be the major growth drivers. However continue put pressure on the profit margins.
stronger
Rupee
will
Source: Hindalco Industries Limited (Business Wire India) CHARACTERISTICS OF ALUMINIUM FOIL MARKET
The applications of Foil could be divided into two major groups i.e packaging applications and non-packaging applications Packaging applications include the products given above For these products, the requirement of packaging is such that it should protect the product from physical and chemical changes and climatic hazards Non-packaging applications include heat exchangers tube fins in air conditioners, capacitors and cable wraps, in which specific properties of the foil such as conductivity are used. As compared to other flexible packaging material, aluminium foil has proved to be the superior material as far as protection of material, convenience in usage and surface finish are concerned. However, in India, aluminium foil has proved to be costly because of higher price of basic material and higher excise duty. Many a time, it is not available in requisite quantity. Owing to the high price and uncertain availability of the foil in the past, many of the user industries like pharmaceutical industry switched over to other packaging material such as glasine poly laminate Some companies introduced blister packs and some companies reduced thickness of the foil Circumstances have thus proved that usage of packaging medium for consumer items depends on its availability, price, and shelf-life desired for the product Depending upon the situation, the appropriate packaging medium is selected The usage pattern, being very sensitive to price and availability, keeps on changing from time to time depending upon the economies of usage of aluminium foil vis-a-vis that of other materials In India aluminium foil industry, there are frequent changes in the usage patterns and specifications of foils, as compared to the foreign countries and therefore, the usage of the foil has remained restricted in variety as well as in quantitative terms
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The growth of foil industry, has thus not kept pace with the growth of its major user industries The past production of foil shows an overall growth rate of about 7% only.
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Market Break Down of Usages Aluminium
Range of Properties and Uses of Aluminium Alloy
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MANUFACTURER/SUPPLIER/EXPORTER OF ALUMINIUM ALLOY INGOTS

Ashapura Steel Address: 114/ A, R.K. Wadi, Shop No. 8, 2nd Parsiwada Lane, Mumbai, Maharashtra - 400 004 Phone: +(91)-(22)-66394870/66394492 Fax: +(91)-(22)-23821566 Mobile / Cell Phone: +(91)-9820469696/9320006141 Website: http://www.ashapurasteel.com/non-ferrous.html Jindal Impex Address: E-384, Phase-VI, Focal Point, Ludhiana, Punjab - 141 010, India Phone: +(91)-(161)-5021500 Fax: +(91)-(161)-2678784 Mobile / Cell Phone: +(91)-9872969707/9878572700 Website: http://www.jindalimpex.com/ J J Aluminium Private Limited Address: Plot No. 117, Road No.6, Kathwada G.I.D.C., Kathwada, Odhav, Ahmedabad, Gujarat - 382 430, India Phone: +(91)-(79)-22901182 Fax: +(91)-(79)-22901182 Mobile / Cell Phone: +(91)-9825773828/9825047875 Vijay Prakash Gupta & Sons Address: No. 3019, Street No. 2, Chuna Mandi, Paharganj, New Delhi - 110 055, India Phone: +(91)-(11)-23586472/23584321 Fax: +(91)-(11)-23585757 Mobile / Cell Phone: +(91)-9811125181 Nisarg Casting Address: 54/b/1, Changodar Industrial Estate, Near Presion Bearing, Chnagodar, Ahmedabad, Gujarat - 382 213, India 23 | P a g e
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Phone: +(91)-(2717)-250128 Mobile / Cell Phone: +(91)-9978914205/9426015205 G. K. Founders Private Limited Address: No. 13, Ranka House, Kale Marg, Bail Bazar Road, Mumbai, Maharashtra - 400 070, India Phone: +(91)-(22)-25141266 Fax: +(91)-(22)-32569042 Mobile / Cell Phone: +(91)-9324258495/9825804585 Maruti Alluminium Private Limited Address: Plot No.- 380, Raod No.- 9, G.I.D.C. Kathwada, Opposite Odhav Octroi Naka, Odhav, Ahmedabad, Gujarat - 382 430, India Phone: +(91)-(79)-22901347/22901330 Fax: +(91)-(79)-22901347 Mobile / Cell Phone: +(91)-9909030758 Manaksia Limited Address: 8/1, Lal Bazar Street, Kolkata, West Bengal - 700 001, India Phone: +(91)-(33)-22210051 Mobile / Cell Phone: +(91)-9830790059/9830052173 Gold Star Alloys Address: Plot No.276, Sector No. 7, Opposite Sahani Gas Industrial PCNDTA, Bhosari, Pune, Maharashtra - 411 026, India Mobile / Cell Phone: +(91)-9822401637 Kamala Metachem Address: No. 3, British Indian Street, 3rd Floor, Room No. 3D, Beside Great Eastern Hotel, Kolkata, West Bengal - 700 069, India Phone: +(91)-(33)-22100681 Fax: +(91)-(33)-22435682 Mobile / Cell Phone: +(91)-9830028623 Vijay Prakash Aeromarine Metals Pvt Ltd Address: B-101, FF, Plot No. 2, 24 | P a g e
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R. G. Complex, Motia Khan, D. B. Gupta Road, New Delhi - 110 055, India Phone: +(91)-(11)-23544854 Mobile / Cell Phone: +(91)-9899097631 Alloy Tech, Bangalore Address: Plot No 22 E, 3rd Main, 5th Cross, Athibele Industrial Area, Anekal, Taluk, Bengaluru, Karnataka - 562 107, India Phone: +(91)-(80)-27820540/25729183 Fax: +(91)-(80)-25729859/30616039 Mobile / Cell Phone: +(91)-9886788183/8105011880 M. G. Metallinkers Private Limited Address: E-6, Government Industrial Area, Bahadurgarh, Haryana - 124 507, India Phone: +(91)-(1276)-242389/23544451 Fax: +(91)-(1276)-242445 Mobile / Cell Phone: +(91)-9315877241/9996465657 Krishna Metals And Alloys Industries Address: No. B-34, Krisna Gopal Estate, Opposite S.B.I. Bank Memco, Char Rasta, Naroda Road, Ahmedabad, Gujarat - 380 001, India Phone: +(91)-(79)-22201882 Fax: +(91)-(79)-22201882 Mobile / Cell Phone: +(91)-9879293970/9327029128 Kiran Aluminium India Private Limited Address: 229-A, 2nd Floor, Kewal Industrial Estate, Next To Big Bazaar, Senapati Bapat Marg, Lower Parel West, Mumbai, Maharashtra - 400 013, India Phone: +(91)-(22)-30406700/30406701 Fax: +(91)-(22)-30406703 Mobile / Cell Phone: +(91)-9869021174/9869021174 Krum Alloys Industries Private Limited Address: W-46 M I D C.Shiroli, 25 | P a g e
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Kolhapur, Maharashtra - 416 212, India Phone: +(91)-(230)-2469331 Fax: +(91)-(230)-2469331 Mobile / Cell Phone: +(91)-9322268661 Metal Cast & Alloys Address: 39, Industrial Estate, Phase-1, Yamunanagar, Haryana - 135001, India Phone: +(91)-(1732)-251315 Fax: +(91)-(1732)-251515 Mobile / Cell Phone: +(91)-9896351615 Baldev Metals Private Limited Address: B-22 Phase 1, Maya Puri Industrial Area., New Delhi - 110064, India Phone: +(91)-(11)-28117476 Mobile / Cell Phone: +(91)-9971400401 Anurag Alloys And Diecast Private Limited Address: Plot No. 57, Sector- 6, Faridabad, Haryana - 121 006, India Phone: +(91)-(129)-2243709 Fax: +(91)-(129)-4061446 Mobile / Cell Phone: +(91)-9811665709/9873146519 Thalco Address: Bileshwar Estate, Kathwada G.I.D.C., Ahmedabad, Gujarat, India Mobile / Cell Phone: +(91)-9913369920/9924377804 G.K.Founders.Private Limited Address: Survey No. 331/2, Plot 5/B, Tipco Road, Masat, Dnh,, Silvassa, Dadra And Nagar Haveli - 396230, India Phone: +(91)-(260)-3290990 Fax: +(91)-(260)-2631812 Strategic Metals Private Limited Address: 106, Commerce Centre, Vishveshwar Nagar Off Aarey Road, 26 | P a g e
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Gujarat Indl Compound, Mumbai, Maharashtra - 400 063, India Phone: +(91)-(22)-28739670/28739671 Fax: +(91)-(22)-28739673 Mobile / Cell Phone: +(91)-9820033076 Srg Aluminium Private Limited Address: 31 Industrial Estate, Gwalior, Madhya Pradesh - 474004, India Phone: +(91)-(751)-4040120 Mobile / Cell Phone: +(91)-9893904567/9993032222 Navkar Metal Address: 94/100, Fanaswadi, Runghta Bhawan Room No.30, 2nd Floor, Mumbai, Maharashtra - 400 002, India Phone: +(91)-(22)-66518883/66595328 Mobile / Cell Phone: +(91)-9324001100 Manju Metals Address: No. 118, Konnur High Road, Ayanavaram, Chennai, Tamil Nadu - 600 023, India Phone: +(91)-(44)-26744009 Fax: +(91)-(44)-26744009 Mobile / Cell Phone: +(91)-9380733884 Prism Metals (P) Ltd. Address: B-28, Mayapuri Industrial Area, Phase- I, New Delhi - 110064, India Phone: +(91)-(11)-66130300 Fax: +(91)-(11)-45082434 International Business Combines Address: The Industrial Square, No. 17-9/2, Begampur, Industrial Area, Sector-35, 39th KM Stone, NH-8, Gurgaon, Haryana - 122 001, India Phone: +(91)-(124)-2210981/26143895 Fax: +(91)-(11)-46039660 27 | P a g e
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Mobile / Cell Phone: +(91)-9811889059 Padmavati Metals Address: No. 902/290, Street No. 9, Shalimar Industrial Area, New Delhi - 110 088, India Phone: +(91)-(11)-27494609 Mobile / Cell Phone: +(91)-9868748304 Century Metal Recycling Private Limited Address: Village Tatarpur, Teh. Palwal, Faridabad, Haryana - 121 102, India Mobile / Cell Phone: +(91)-9873666455 N. F. Casting India Address: No. 1567, Shiv Shanker Nagar, Near Hindu Girls College, Jagadhri, Yamunanagar, Haryana - 135 003, India Phone: +(91)-(1732)-222315 Fax: +(91)-(1732)-222315 Mobile / Cell Phone: +(91)-9416022315/9355306130 Bharath Aluminium Company Limited Address: Welfare Building, Plant I, Commercial Deptartment Balco Nagar, Korba, Chattisgarh - 495 684, India Phone: +(91)-(7759)-240383/242052 Fax: +(91)-(7759)-240626 Mobile / Cell Phone: +(91)-9981144330 Sainath Industries Address: 34, Rungta Bhavan, 94/100, Fanaswadi, Mumbai, Maharashtra - 400002, India Phone: +(91)-(22)-56394493 Fax: +(91)-(22)-56548412 Univenture Corporation Address: No. 4, Sial Layout, Nelson Square, Nagpur, Maharashtra - 440 013, India Phone: +(91)-(712)-2594567 Fax: +(91)-(712)-6629645 28 | P a g e
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Kundan Traders, Kolkata Address: 57/6 B.T.Road, Kolkata, West Bengal - 700 002, India Phone: +(91)-(33)-25573131 Pankaj Metals Corporation Address: S/15, Vikram Chambers Ashram Road, Ahmedabad, Gujarat - 380009, India Phone: +(91)-(79)-27546252/27546964/32951521 Fax: +(91)-(79)-66611515 Maken Alloys Address: Logate More, Kathua, Jammu & Kashmir - 184102, India Phone: +(91)-(1922)-203241/203242 Fax: +(91)-(1922)-237794/236114 Mobile / Cell Phone: +(91)-9906022324/9906022317 J. S. B. Aluminium Address: Phase 1, Lane No. 7, S.I.D.C.O., I.G.C., Samba, Jammu & Kashmir - 184 121, India Phone: +(91)-(1923)-246385/28525421 Fax: +(91)-(11)-28525421 Mobile / Cell Phone: +(91)-9711288899/9811160663 Maruti Alluminium Private Limited Address: Plot No: 380, Road No: 9, Gidc Kathwada, Kathwada,, Ahmedabad, Gujarat - 382430, India Phone: +(91)-(79)-22901330/22901347 Harsh International Address: 634, G.I.D.C., Phase-Ii Dared, Jamnagar, Gujarat - 361004, India Phone: +(91)-(288)-2730417/2730125 Fax: +(91)-(0288)-2730517 Mobile / Cell Phone: +(91)-9978308080 Monarch Overseas Address: 315, G.I.D.C., Phase Ii, Dared Jamnagar, Jamnagar, Gujarat - 361004, India 29 | P a g e
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Phone: +(91)-(288)-2730217 Fax: +(91)-(288)-2730339 N. H. Engineering Industries Address: Plot No. 15, Phase No. 2, G.I.D.C., Vithal Udyognagar Post Karamsad, Anand, Gujarat - 388 120, India Phone: +(91)-(2692)-237226 Fax: +(91)-(2692)-230346 Mobile / Cell Phone: +(91)-9879795380 Sagar International Private Limited Address: 5, Hanuman Road, Delhi - 110 005, India Phone: +(91)-(11)-23658876 Sri Venkateshwara Non Ferrous Foundry Address: 19/5, Industrial Area, Azamabad, Hyderabad, Andhra Pradesh - 500 020, India Phone: +(91)-(40)-27603829 Fax: +(91)-(40)-27656218 Perfect Aluminium Alloys Address: 578 N. H. Road, Marakadai, Near To Bangalore Hotel, Coimbatore, Tamil Nadu - 641 001, India Phone: +(91)-(422)-2391671 Samsung Overseas Limited Address: 104, Adishwar Apartments, Firozshah Road, New Delhi - 110 016, India Phone: +(91)-(11)-45727272 Fax: +(91)-(11)-45727272 Mobile / Cell Phone: +(91)-9811067809 Bhawani Wire & Cable Address: Lane No.3, Phase-I, SIDCO Industrial Complex, Bari Brahmana, Jammu, Jammu & Kashmir - 181 133, India Phone: +(91)-(1923)-220878 Mobile / Cell Phone: +(91)-9419197099 Shri Ganesh Metal Rolling Mill & Engineering Works 30 | P a g e
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Address: Unit-Ii, Block No. 271/1-C/1 Gokul, Hubli, Karnataka - 580 026, India Phone: +(91)-(836)-2210674/2310434 Fax: +(91)-(836)-2310385 Mobile / Cell Phone: +(91)-9448342370/9686081663 Lila Aluminium Industries Private Limited Address: Gut No. 16, Naigaon Khandewadi, Paithan Taluka, Aurangabad, Maharashtra - 431 107, India Phone: +(91)-(240)-2694533 Mobile / Cell Phone: +(91)-9922442388 Maken Alloys Address: Logate More, Near Railway Crossing Kathua, Kathua, Jammu & Kashmir - 184102, India Phone: +(91)-(1922)-203241 Mobile / Cell Phone: +(91)-9906022298/9906022317 Utlak Aluco Limited Address: F-140, Delta-i, Greater Noida, Noida, Uttar Pradesh - 201 305, India Phone: +(91)-(120)-2572245 Mobile / Cell Phone: +(91)-9871460653
We or Our Organization are not concerned with any of the contacts provided above. We do not bear any responsibility or guarantee Quality of their product. We do not know them neither do they.
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MANUFACTURING PROCESS
When aluminium is to be fabricated it is important to start with Ingots/billets or slabs as free from segregation and blow holes as possible.
MANUFACTURING OF INGOT FROM SCRAPE

A methods is being used where by molten aluminium is fed to a water cooled mold with a moveable bottoms. The rate of flow of metal is synchronised with the rate of solidification and the bottom of the mold is lowered at the calculated rate. The solidified metal shrinks away from the wall of the mold and allows the resulting Ingots to drop with a moveable bottom and a solid uniform casting of any desired length is thus obtained. The furnace contain molten aluminium which flows through the discharge spout. Two ingots can be simultaneously cast with the flow each adjusted by valve.
MELTING & TREATMENT OF SECONDARY ALUMINIUM :The treatment of aluminium scrap has become complicated by the increasing number of aluminium alloys which have come on the market in recent year. Some degree of sorting is possible based on the uses to which the object composing the scrap have been put. Bending test are also used and in some plants the spectrograph /spectrometer is employed. The men engaged in sorting have in many cases become highly skillful by experience. The furnace usually oil or gas fired are used for melting and the atmosphere in regulated to minimize oxidation. It is desirable when possible to immerse thin scrap below the surface of the bath to inhibit oxidation during melting. A furnace is in used for melting aluminium scrap in which a portion of the hearth is external but contiguous with the interior portion. This scrap is submersed in the exterior portion of the bath and subjected to slow agitation to promote rapid melting. The agitation together with the rather high heat conductivity of the bath promotes heat exchange with the heated interior and prevents the exterior portion from solidifying. 32 | P a g e
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FLUXING AND FLUSHING Fluxing and flusing of aluminium melts is practiced mainly for two reasons. A) To provide more effective separation of metal and dross. B) To remove dissolved hydrogen and entrapped dross. Gaseous fluxes used to flush or purge the melt include nitrogen, helium, argon and chlorine. The gases are slowly bubbled through the melt for hydrogen removal. Hydrogen dissolved in the aluminium diffuses into the gas bubbled and is carried away. Dross separation is probably a mechanical action of the inert gas bubbles carrying oxides to the surface. Flushing is carried out by skimming off surface dross and then bubbling the dry gas through the melt. Fluxing with solid fluxes is a simpler procedure, flux to the extent of about 0.10lb per 100lb i.e of metal is added to the melt by forcing it to the bottom of the bath in a perforated container. Aluminium and Zinc chloride, as well as a number of proprietary composition containing these compounds, are used as solid fluxes.
MANUFACTURING OF SHEET & FOIL

There are two methods of producing Aluminum Sheet/Foil. One from using Caster where molten metal is directly used to manufacture sheet and foil and the other is from ingot. The method of producing using Caste i.e. directly from molten metal is relatively new and is costly. Also, for manufacturing sheet/foil from scrap, it is less suitable as, it is difficult to maintain the composition of molten metal due to unknown composition of scrape. Thus, currently for Indian market, manufacturing using Aluminum Ingot is more suitable, as the composition of Ingots can be easily maintained and fresh aluminum Ingots can be used whenever necessary. The ingot is usually cooled after casting to room temperature and then re-heated to around 500 C prior to successive passes through a 33 | P a g e
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hot rolling mill where it is reduced in thickness to about 4 - 6 mm. The temperature of pre-heat of the ingot and the time held at that temperature is important for some alloys since a process of homogenization takes place which renders the material in the best condition for rolling and the achievement of subsequent properties. The strip from the hot rolling mill is coiled for transport to the cold mill which might be on the same site or elsewhere. Cold mills, in a wide range of types and sizes are available; some are single stand, others 3 stand and some 5 stand. Cold rolling speeds vary but modern mills operate at exit speeds as high as 3000 m per minute. The foil of uniform gauge and desired tolerance is made by subjecting this foil-stock through a series of cold rolling passes, on one or a number of rolling mills The minimum thickness to which the foil is cold rolled, is 0.006 mm, achieved through pack rolling, i.e., rolling of two foils together. At the end of cold rolling operations, the foil is annealed in order to fully soften it and impart the characteristics like dead fold and easy Work ability. Annealing also burns off the oil left on the foil surface. Annealing thus makes the foil free from oil and fully sterile. The annealed foil, is then subjected to the various treatments as per requirements: a) b) c) d) e) f) g) h) i) Separation of pack rolled foils, Slitting to desired widths, including edge trimming, Embossing, Sheet making and cutting to length, Application of adhesives, wax, lacquer etc., Lamination with paper, paper board, LDPE, Single or multi colour printing, Slitting of laminated composite, Packing in desired lengths or weights
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A modern complex including melting furnaces, asting facilities, pre-heat furnaces, hot mill, cold mill and annealing furnaces involves a very large capital investment which can only be fully justified on financial grounds if a big market is assured. Obviously, if such facilities are not fully utilized the economic viability is threatened. As indicated above, however, hot mill coil can be obtained for further reduction in cold mills of lower capacity/speed/ complexity.
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PROCESS FLOW SHEET (Ingot to Scrape)
Flow sheet of Aluminum Sheet/Foil manufacturing is same as that given in 3D graphics in Process description.
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PRINCIPLES OF PLANT LAYOUT

Some of the guiding principles for detailed plant layout will be discussed for the benefit of those making layout decisions for the first time.
Storage Layout: Storage facilities for raw materials and intermediate and finished products may be located in isolated areas or in adjoining areas. Hazardous materials become a decided menace to life and property when stored in large quantities and should consequently be isolated. Storage in adjoining areas to reduce materials handling may introduce an obstacle toward future expansion of the plant. Arranging storage of materials so as to facilitate or simplify handling is also a point to be considered to design. Where it is possible to pump a single material to an elevation so that subsequent handling can be accomplished by gravity into intermediate reaction and storage units, costs may be reduced. Liquids can be stored in small containers, barrels, horizontal or vertical tanks and vats, either indoors or out of doors. Equipment Layout: In making a layout, ample space should be assigned to each piece of equipment; accessibility is an important factor for maintenance. It is extremely poor economy closely into a building. A slightly will cost little more than one that will indeed be small in comparison extracted if, in order to iron out expanded. to fit the equipment layout too larger building appears necessary is / that crowded. The extra cost with the penalties that will be the kines, the building must be
The operations that constitute a process are essentially a series of unit operations that may be carried on simultaneously. These include filtration, evaporation, crystallization, separation, and drying. Since these operations are repeated several times in the flow of materials, it should be possible to arrange the necessary equipment into groups of the same kinds. This sort of layout will make possible a division of operation labor so that one or two operators can be detailed to tend all equipment of a like nature.
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The relative levels of the several pieces of equipment and their accessories determine their placement. Although gravity flow is usually preferable, it is not altogether necessary because liquids can be transported by blowing or by pumping, and solids can be moved by mechanical means. Gravity flow may be said to cost nothing to operate, whereas the various mechanical means of transportation involve the first cost of the necessary equipment and the cost of operation and maintenance. But material must be elevated to a level where gravity flow must start. However, gravity flow usually means a multistory layout, whereas the factors favoring a single-story plant may largely, if not entirely, compensate for the cost of mechanical transportation. Access for initial construction and maintenance is a necessary part of planning. For example, overhead equipment must have space for lowering into place, and heat-exchange equipment should be located near access areas where trucks or hoist can be placed for pulling and replacing tube bundles. Thus, space should be provided for repair and replacement equipment, such as cranes and forked trucks, as well as access way around doors and underground hatches. Safety: A great deal of planning is governed by local and national safety and fire code requirements. Fire protection consisting of reservoirs, mains, hydrant, hose houses, fire pumps, reservoirs, sprinklers in building, explosion barriers and directional routing of explosion forces to clear areas, and dikes for combustible-product storage tanks must be incorporated to protect costly plant investment and reduce insurance rates. Plant Expansion: Expansion must always be kept in mind. The question of multiplying the number of units or increasing the size of the prevailing unit merits must be studied. Suffice it to say that one must exercise engineering judgment; that as a penalty for bad judgment, scrapping of present serviceable equipment constitutes but one phase, for shutdown due to remodeling may involve a greater loss of money than that due to rejected equipment. Nevertheless, the cost of change must sometimes be borne, for the economies of larger units may, in the end, make replacement imperative. Floor Space: Floor space may or may not be a major factor in the design of a particular plant. The value of land may be a considerable item. The engineers however, follow the rule of practicing economy of floor space, consistent with good housekeeping in the plant land with proper consideration given to line flow of materials, access to 38 | P a g e
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equipment, space to permit working on parts of equipment that need frequent servicing, and safety and comfort of the operators. Utilities Servicing: The distribution of gas, air, water, steam, power, and electricity is not always a major item, in as much as the flexibility of distribution of these services permits designing to meet almost any condition. But a little regard for the proper placement of each of these services, practicing good design, aids in of operation, orderliness, and reduction in costs of maintenance. No pipes should be laid on the floor or between the floor and the 7-ft. level, where the operator must pass or work. Chaotic arrangement of piping invites chaotic operation of the plant. The flexibility of standard pipe fittings and power-transmission mechanisms renders this problem one of minor difficulty. Building: After a complete study of quantitative factors, the selection of the building or buildings must be considered. Standard factory buildings are to be desired, but, if none can be found satisfactory to handle the space and process requirements of the chemical engineer, then a competent architect should be consulted to design a building around the process - not a beautiful structure into which a process must fit. It is fundamental in chemical engineering industries that the buildings should be built around the process, instead of the process being made to fit building of conventional design. In many cases only the control area requires housing, with the process equipment erected outdoors. This is known as outdoor construction and such layouts should be considered for many types of plants. What consideration must be given to buildings depends upon conditions. If the designer must adapt his design to fit an old building or building space already erected, his problem is cut out for him and he has limiting conditions. However, the selection of the design of a new building to meet the requirements of the process is more scientific. In this case, one finds before him practically all types of standard building, built in units, interlocking or otherwise, ready for shipment and erection. Throughout chemical industry, much thought must be given to the disposal of waste liquors, fumes, dusts, and gases. Ventilation, fume elimination, and drainage may require the installation of extra equipment. This may involve the design of the individual pieces of operating equipment, or it may require the installation of isolated equipment. If the latter be the case, the location of such equipment 39 | P a g e
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where it will not interfere with the flow of materials in process should be practiced. The selection of the proper piece of equipment for doing this service is also an important point; the less attention the ventilating, fume, or waste-elimination systems require, the better service they may render. Sometimes air conditioning of the plant is called for and may require an elaborate setup. But the installation of such equipment, when needed, pays in better service from operators, less discomfort, greater production, and a better morale than when such conditions are left to nature. It must be recognized that there is not only one solution to the problem of layout of the equipment. There are many rational designs. Which plant to adopt must be decided upon after exercise of engineering judgement and after striking a balance between the advantages and disadvantages of each possible choice. Material-handling Equipment: Consideration of equipment for materials handling is only a minor factor in most cases of arrangement, because of the multiplicity of available materials handling devices. But where this operation is paramount in a process, serious thought must be given to it. Again it should be said that engineering judgement must be exercised. Whenever possible, one should take advantage of the topography of the site location, and the process involved. Railroads and Roads: Existing or possible future railroads and highways adjacent to the plant must be known in order to plan rail siding and access roads within the plant. Railroad spurs and roadways of the correct capacity and at the right location should be provided for in a traffic study and over-all master track and road plan of the plant area. Some of the factors in rail-track planning are: 1. Existing and future off-site main rail facilities 2. Permissible radius of curvature for spurs - consult local rail authorities. 3. Provision for traffic handling - arrangement of spurs and ladder track and switching. 4. Adequate spur facilities a. Loading and unloading facilities for initial plant construction and subsequent operations. b. Rack stations for liquid handling c. Storage space for full and empty cars d. Space for cleaning and car repairs.
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Major provisions in road planning for multipurpose service are: 1) A means of interplant movement for road traffic, both pedestrian and vehicular 2) Heavier and wider roads for large-scale traffic. 3) Routing of heavy traffic outside the operational areas 4) Roadways for access to initial construction, maintenance, and repair points. 5) Roadways to isolated points, storage tanks, and safety equipment, such as fire hydrants.
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PLANT LOCATION FACTORS

Factors which generally apply to the economic and operability aspect of plant site location are classified into two major groups. The primary factors listed apply to choice of a region, whereas the specific factors looked at in choosing an exact site location within the region. All factors are important in making a site location selection. Primary Factors 1. Raw-material supply: a. Availability from existing or future suppliers b. Use of substitute materials c. Distance 2. Markets: a. Demand versus distance b. Growth or decline c. Inventory storage requirements d. Competition - present and future. 3. Power and fuel supply: a. Availability of electricity and various type of fuel b. Future reserves c. Costs 4. Water supply: a. Quality - temperature, mineral content, bacteriological content b. Quantity c. Dependability - may involve reservoir construction d. Costs. 5. Climate: a. Investment required for construction b. Humidity and temperature conditions c. Hurricane, a tornado, and earthquake history
Specific Factors
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a. Availability of various services and projected rates 1. Rail - dependable for light and heavy shipping over all distances 2. Highways - regularly used for short distance and generally small quantities 3. Water - cheaper, but may be slow and irregular 4. Pipeline - for gases and liquids, particularly for petroleum products 5. Air - for business transportation of personnel 7. Waste disposal: a. Regulations laws b. Stream carry-off possibilities c. Air-pollution possibilities 8. Labor: 1. Availability of skills 2. Labor relations - history and stability in area 3. Stability of labor rates 9. Regulatory laws: a. Building codes b. Zoning ordinances c. Highway restrictions d. Waste-disposal codes 10. Taxes: a. State and local taxes 1. Income 2. Unemployment insurance 3. Franchise 4. Use 5. Property b. Low assessment or limited term exemptions to attract industry. 11. Site characteristics: a. Contour of site b. Soil structure c. Access to rail, highway, and water d. Room for expansion e. Cost of site f. Site and facilities available for expansion on present 43 | P a g e
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company-owned property 12. Community factors: a. Rural or Urban b. Housing costs C. Cultural aspects - churches, libraries, theatres d. School system e. Recreation facilities f. Medical facilities - hospitals, doctors 13. Vulnerability to wartime attack: a. Distance important facilities b. General industry concentration 14. Flood and fire control: a. Fire hazards in surrounding area b. Floor history and control
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EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION: This represents reduction in the utility and value of a capital asset because of wear and tear, lapse of time, obsolescence etc. The use of an asset helps in the generation of revenue for the business. A part of the cost of the asset, estimated to be equal to the reduction in the utility and economic life of the asset, because of its use, is charged off by way of depreciation charge against such revenue to arrive at the true profits.
2. FIXED ASSETS:
Represent those assets which remain permanently (till their useful lives) with the business and are not meant for resale. These assets are acquired for use in the operation of business and help in the generation of revenue for the business. These include land and building, plant and machinery etc. 3. WORKING CAPITAL: This represents the total expenses on Raw materials, utilities & overheads, and salaries & wages, for a specified period of time. 4. BREAK-EVEN POINT: This represents the level of output and sales at which the firm is able to recover all its expenses-both fixed and variable. In other words it indicates the level of output and sales at which the firm is neither making profit nor incurring any loss. Level of output more than the Break-Even Level generates profit for the firm. 5. OTHER FIXED EXPENSES: These represent expenses which remain fixed irrespective of changes in level of output. In other words these are the expenses which the firm has to incur whether there is production or not. These include expenses such as preliminary and Preoperative expenses, Insurance and Freight, Technical Know-how and Consultancy, Erection & Commissioning etc. building, insurance, etc.
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6. MARGIN MONEY: This represents that part of the cost of project which the promoter has to meet from his own resources. This is the contribution which the promoter must make to the equity of the project for becoming eligible for assistance from financial institutions/Banks. 7. TERM LOANS: Represent Loans which are repayable over a long period of time. These loans are meant for meeting capital expenditure of the project. 8. TOTAL LOAD: It is the ratio of the maximum power consumed in KWH in a particular period of time to the number of operating hours of the unit in that particular period.
9. LAND AREA/MAN POWER RATIO: It is the ratio of manpower utilised per unit area of land required for operating the unit.
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SUPPLIERS OF PLANT & MACHINERIES FURNACE HIGH TEMP FURRNACES LTD. 1C, PHASE-II, PEENYA IND. AREA, BANGALORE - 560 058 KARNATAKA, PH: 91-80-28395917, 28394076 D. N. Reddy, MD A P MOTRONIX PVT LTD 3-18-3, Pragathi Nagar, Ramanthapur Hyderabad-500013, Andhra Pradesh Phone: 040-27038560/27031929 Email: apmotronix@satyam.net.in Mr. Manwani ADOR TECHNOLOGIES LTD Plot No.53, 54 & 55, F-II Block, MIDC, Pimpri Pune-411018, Maharashtra Phone: 020-7470225/7476009 Email: avtulpule@adorians.com Mg. Director ADVANCE HEATING SYSTEMS 207, Vardhman Complex 8, Facility Centre, Mayapuri Industrial Area-II New Delhi-110064 Phone:011-25139315, 25403798, (r) 25613649 Email: advanceheat@yahoo.com Mg. Director AJANTA SCIENTIFIC INDUSTRIES Science Market, Near Hargotal Dharmashala Ambala Cantt.-133001, Haryana Phone:0171-2642428, 2630814 (O), (R) 2650316 Email: ajantaseindia@hotmail.com
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Mg. Director AMBICA ENGINEERING WORKS # 16/A, 1st Main, Modi Hospital Road, West Of Chord Road, 2nd Stage Bangalore, Karnataka Phone:080-3495370 V. S. Prasanna, Marketing Mgr APNA SCIENTIFIC SUPPLIES PVT LTD M-2, Industrial Estate, Guindy Chennai-600032, Tamil Nadu Phone: +91 44 22340963, 22340630 Mr. Kapahi ASSOCIATED INDUSTRIAL FURNACES PVT LTD F-9, Sector-Xl Noida-201301, Uttar Pradesh Phone: 0120-2529187, 2529169 Email: aifdli@ndb.vsnl.net.in;aifdli@vsnl.com
COOLING TOWER Lalit Narang, Proprietor A TO Z ENGINEERS & CONSULTANTS 915, Vishal Towers, 10, District Centre, Janakpuri, New Delhi-110058 Phone: +91 11 25619462, 25551832 Email: coolflowcoolingtowers@yahoo.co.in Yogesh Pujari, Export Mgr ADVANCE REINFORCED PLASTICS PVT LTD 405/406, Span Centre, R K Mission Marg, Santacruz (W) Mumbai-400054, Maharashtra Phone: 022-26001067, 26001068 Email: coolingtowers@vsnl.com Mr. Kailash Magolra ALBATRON FINE CHEM LTD 48 | P a g e
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40, Dlf Industrial Area, Alishan Building, Kirti Nagar New Delhi-110015 Phone: 011-25161151/25114789/25100768 Mr. Ravinder B D T LTD Sri Madurakripa Towers, 2nd Floor, New No. 51, North Boag Road, T. Nagar Chennai-600017, Tamil Nadu Phone: 044-28235971/28235977 Email: mail@bdtltd.com
Mr T S Rao EAST COAST STRUCTURALS 96/3, Sidco Estate, Ambattur Chennai-600098, Tamil Nadu Phone: 044-26252850 Davindar Sapru, Sales Mgr AADI HEAT EXCHANGER PVT LTD D-83, Hosiery Complex, Phase II Ext. Noida-201305, Uttar Pradesh Phone: +91 120 2460073, 2460073 Email: aadihe@hotmail.com Mr. Ajay D M POLYMERS Near, Chungi,, Daultabad Road, Gurgaon, Haryana Phone:0124-2469780, 3095483, 9810074583 Email: info@dmpolymers.com WATER PUMP MR. A S THAPAR (CHAIRMAN) ALLENA AUTO INDUSTRIES LTD B-68, WAZIRPUR, INDL. AREA DELHI-110052 Phone: 011-27373704, 27121008 Email: alenauto@bol.nt.in;nlchanda@allenaauto.com 49 | P a g e
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MR. MANISH PATEL AMIDHARA INDUSTRIES L-92, GIDC ESTATE, BEHIND OLD WATER TANK, ODHAV AHMEDABAD-382415, GUJARAT Phone: 079-3870420/2876420 M. Z. BANDUKWALA, MD ANCO MOTORS 248/250,, ABDUL REHMAN STREET MUMBAI-400003, MAHARASHTRA Phone: +91 22 3424764 3400605 Email: anco@vsnl.com MRS. MUKHERJEE B E PUMPS PVT LTD C/401, CRYSTAL PLAZA, NEW LINK ROAD, ANDHERI (WEST), MUMBAI-400053, MAHARASHTRA Phone:912226733510 Email: be@vsnl.com MR. BABU KHAN & MR. DISHAD KHAN (DIR) B K HI-TECH ENGINEERING, C-334,, SECTOR-10, NOIDA-201301, UTTAR PRADESH Phone: 0120-2557355, 9811642485,
MR. A K BEHAR B S PUMPS PVT LTD BASAI ROAD GURGAON-122001, HARYANA Phone: 0124-2321052, 2329934 Email: bspumps@hotmail.com;bsp@mantraonline.com
MR. C P DAHRA/MR. SAMIR DAHRA DAHRA ENGG CO 35 VISHWAKARMA INDL. AREA, SECTOR 24, NEAR DHARAMKANTA, MUJESSAR, FARIDABAD-121005, HARYANA Phone: 0129-2232388, 2232684, 4023153, 9811211965, 2241519 Email: dec@ndf.vsnl.net.in, dahra@vsnl.com
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MR. DINESH PATEL DEV INDUSTRIES 13, PRAGATI INDUSTRIAL ESTATE, OPP. JAGANNATH ESTATE, GUJARAT BOTTLING ROAD, RAKHIAL AHMEDABAD-380023, GUJARAT Phone: 079-2748716/98250-38773 HARGOVIND BATRA, MD H F H AUTO PUMPS SURVEY NO. 115, HISSA NO. 6, GHODBUNDER ROAD THANE-401104, MAHARASHTRA Phone: +91 22 285 50156,28550158 MR. KAPIL BHATIA (EXP MGR) HAMMER AUTO INDUSTRIES 374 PUNJA SHARIF, KASHMERE GATE DELHI-110006 Phone: 011-23975863 Email: polfa_pumps@vsnl.net;hpolfa@nde.vsnl.net.in R. K. BANSAL, PARTNER HINDUSTAN TRADING CORP 4, LIBERTY HOUSE, MAVDI PLOT RAJKOT-360004, GUJARAT Mobile:Phone: +91 281 388 541,388630 Email: info@htcorporation.com; htc@wilnetonline.com MR. KAMAL KAPURIA (DIR) IAEL PUMPS LTD C-60-B, KALKAJI NEW DELHI-110019 Phone: 011-26447880, 26473243, Email: enmax@satyam.net.in JAYANT DAVE, OWNER JAYANT ENGINEERING WORKS 46/2/1B, KALA HALAI INDUSTRIAL ESTATE, PUNE SATARA ROAD PUNE-411009, MAHARASHTRA Phone: +91 20 422 0244 Email: jayant_19@usa.net 51 | P a g e
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B. LANGETARTELS K B S PUMPS LTD MAKER CHAMBERS, NO. III/126, NARIMAN POINT MUMBAI-400021, MAHARASHTRA Phone: 022-22854237/4242/22840614 Email: ermohan@ksb.co.in Mg. Director KAFILA GROUP OF COMPANIES 32, RAJSTHANI UDYOG NAGAR, G T ROAD, AZADPUR NEW DELHI-110033 Phone:011-55457319 RAKESH KAD, MD KAD ENTERPRISES 13-Y, THE MALL PATIALA-147001, PUNJAB Phone: +91 175 354 433 Mg. Director KHADIKAR SALES & SERVICES LTD 1ST FLOOR VRAJ BHOOMI COMPLEX, C G ROAD, NAVRANGPURA AHMEDABAD-380009, GUJARAT Phone: 079-26420318 Email: rajmayur@icenet.net Mg. Director KISHOR PUMPS PVT LTD C-46, BALI NAGAR, NEAR RAJA GARDEN NEW DELHI-110015 Phone:011-25933920, 25464912 Email: delhi@kishorpumps.com MR. RAKESH KOCHHAR KOCHHAR BROTHERS HADIABAD, PHAGWARA, PUNJAB Phone:01824-62307/(R)2220578 Email: kochhar_brothers@vsnl.net.in 52 | P a g e
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MR. ANIL MALHOTRA MOON PAPER & MACHINERY PVT LTD 32, RAJASTHANI UDYOG NAGAR, G T KARNAL ROAD, DELHI-110033 Phone: 011-27139462, 27243593, 27139463, Email: kafila@vsnl.com MR. MILIND S. WALVEKAR OM ENTERPRISES D-113, ANGOL INDL. ESTATE, BELGAUM, KARNATAKA Phone: 918312441694 Email: milind0012@rediffmail.com MR. ASHISH SHAH PARAS ENGINEERING COMPANY ROYAL BUILDING, OPP MAHALAXMI PETROL PUMP, KADIAKUI, RELIEF ROAD, AHMEDABAD-380001, GUJARAT Phone: 917922131338/55441600 Mg. Director PENTAFOUR PRODUCTS LTD AUTO DIVN PENTAFOUR TOWERS, 1ST MAIN ROAD, UNITED COLONY CHENNAI-600024, TAMIL NADU Phone: 044-24836934 Email: pentra@md2.vsnl.net.in MR. D. C. POTTADAR POWER & MACHINERY INDIA PVT LTD 3, MANGOE LANE, GROUND FLOOR KOLKATA-700001, WEST BENGAL Phone: 033-248-2047 MR. HITESH D. RAMANI RADHA ENTERPRISES 10/3, BHAKTINAGAR ST. PLOT RAJKOT-360002, GUJARAT Phone: 0281-2462206
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MR A V SHANKARAN RAPID AUTO COMP PVT LTD 21-B, BALAJI NAGAR, PADI CHENNAI-600050, TAMIL NADU Phone: 044-26541819 MR. RAMBHAI PATEL SAGAR PUMPS(INDIA)LTD 135, BANNER INDIA ESATE OPP, SOMA TEXTILE, RAKHIAL AHMEDABAD-380023, GUJARAT Phone: 079-2743182/2742579 K. SAMPATHKUMAR, MD SAM TURBO INDUSTRY LTD BHARATI PARK, CROSS ROAD NO 7, P B NO 2725, COIMBATORE-641011, TAMIL NADU Phone: +91 422 436264, 441155 P. D. JOSHI, MANAGER SHREE SAINATH INDUSTRIES S S HOUSE, OPP. SUMIN PARK, G.D. HIGH SCHOOL ROAD, SAIJPUR BOGHA AHMEDABAD-382345, GUJARAT Phone: +91 79 2820363, 2821763 Email: ssi@wilnetonline.net Mg. Director SUGUNA MACHINE WORKS LTD 707, AVANASHI ROAD COIMBATORE-641018, TAMIL NADU Phone: 0422-2215512 Email: sugcbetk@md3.vsnl.net.in Mg. Director WALKAR AUTOMOTIVES PVT LTD 20, SECTOR-4,, BALLABGARH FARIDABAD, HARYANA Phone: 0129-2240061,62, Email: walkarauto@vsnl.com COMPRESSOR 54 | P a g e
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Raj Patni, Director A N R ASSOCIATES PVT LTD 2A, Satyam, 142/1A, Sarat Bose Road Kolkata-700029, West Bengal Phone: +91 33 24749048, 24760112 Email: patni@cal.vsnl.net.in R. Jetley, Sales Mgr AA TRANSWORLD COMPRESSOR TECHNOLOGIES LTD 12, Ashok Chakra - I, K G Park Pune-411001, Maharashtra Phone: +91 20 631 676 Email: sale@transworld-compressor.com Mg. Director AERO ENGINEERS Plot No. 3419, GIDC Phase-IV, Vatva Ahmedabad-382445, Gujarat Phone: 079-5840720, 5841295, 5840298 Email: aero@icenet.net Vipul Rathod, Proprietor AIR COMP ENTERPRISE 9, Lati Plot, Sadgurunagar Rajkot-360003, Gujarat Phone: +91 281 2456863, 2459187 R. K. Malhotra, Purchasing Mgr AIRSERCO PVT LTD B-10/1, Okhla, Phase-II New Delhi-110020 Phone: +91 11 263 83570, +91 11 263 83569 Email: parveen@airserco.com Sanjeev Rishi, Marketing Mgr ALFA FLEXITUBES PVT LTD 1726 & 1743, Modern Industrial Estate Bahadurgarh-124507, Haryana 55 | P a g e
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Phone: +91 1276 268 119, +91 1276 267 175 Email: alfaflexitubes@eth.net Anil Kumar Hirjee, Director ATLAS COPCO INDIA LTD 408-410, Vishwa Sadan, 9 District Centre, Janakpuri New Delhi-110058 Phone: +91 11 25590616, 25590611 Email: del.copco@aworld.net D.G. SET Mg. Director NICE INTERNATIONAL 193, Sarupa Mohalla, Garhi, East Of Kailash, New Delhi-110065 Phone: 011-26282823, 26289385, 26282816 Email: maan@ndf.vsnl.net.in Mr. Prakash Bhatia POWERSET INDIA PVT LTD Bhatia Building, 26/27, Errabalu Street, Chennai-600001, Tamil Nadu Phone: 044-25233889/25228539/25244320 Email: powerset_india@yahoo.co.in Mr. M.K. Sahni SAHNI GENERATORS REPAIRING WORKS A-33, Barra-6, Janta Nagar Kanpur, Uttar Pradesh Phone: 0512-283791 Email: mksahni@hotmail.com Mr. Zakir SONATA INDUSTRIAL ELECTRONICS 109, Favurite Industrial Estate, Masrani Lane, HallavPul, Kurla, 56 | P a g e
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Mumbai-400070, Maharashtra Phone: 022-25033405 Email: sonospeed@vsnl.net Mr. N.R . Satyanarayana Rao SURYAKIRAN ENGINEERS & FABRICATORS 5-4-146, M.G Road, Ranigunj, Secunderabad-500003, Andhra Pradesh Phone: 040-55311360/27541664/9848054135 Rajesh Dhruv, CEO DHRUV EXPORTS 705/18, Phase IV, G.I.D.C. Estate, V.U.Nagar-388121, Gujarat Phone: +91 2692 236 698, +91 2692 235 344 Email: bellowd@wilnetonline.net Mr. C.T. Shah / Mr. Jatin Shah HARSH MARINE 414, Nr. Shiv Shakti Petrol Pump, Kathwa, Alang, Bhavnagar, Gujarat Phone: 0278-2434106, 2427321 Email: harshmarine1@rediffmail.com Mr. Stanley INTERNATIONAL ACOUSTIC SYSTEMS J. Rayappa Farm House, Virgonagar Post Bangalore-560049, Karnataka Phone: 080-5616924 Mr. Jagesh Shah PARSHVANATH ELECTRIC CO 3711/A/1, Ph 4, GIDC, Vatva Ahmedabad-382445, Gujarat Phone: 079-5840705/5841795/2141931 Email: parshvanath@icenet.net 57 | P a g e
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Manoj Joshi, Manager R M S CORP 80, Adbul Rehman Street Mumbai-400003, Maharashtra Phone: +91 22 234 35065 Email: rms_corp@vsnl.net Mr. Niraj Sharma SHARMA ENGG WORKS S-18/7, Opp. Uco Bank, Ind. Area Jalandhar, Punjab Phone:0181-883148/2290839/2292124 Email: sharmaengg@swiftxs.com Mr. Sunil Oza SHREEJI STEEL CORPORAION 154/155, Madhav Darshan, Waghawadi Road Bhavnagar-364001, Gujarat Phone: 0278-22411168/22411268/22422854 Email: interlink92@hotmail.com Mr. L. Nanjaiah SRI VINAYAKA VIDYUT MOTORS A-6, Ngef Industrialestate, Mahadevapura Bangalore-560048, Karnataka Phone: 080-8524276/(R)5270957 S. K. Gupta, CEO AVK-SEG & CONTROLS (I) LTD C-60, Phase II, Noida Dist., Gautam Budh Nagar Noida-201305, Uttar Pradesh Phone: +91 120 256 7114,2567115 Email: drgupta@leroy.co.in CRANES MR. ANCHIT JAIN A M ASSOCIATES 58 | P a g e
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A-602, MAYUR DHWAJ SOCIETY, PATPARGANJ, NEW DELHI-110092 Phone:9818211880, MR. DIMPY A-1 CRANE SERVICE GUPTA ARCADE, MAYA PURI, FACILITY CENTRE, NEW DELHI-110064 Phone:011-25146692 K. RAVI, PARTNER A1-ROTOMECHANICAL EQUIPMENTS PLOT NO. 70, NEHRU NAGAR, OLD MAHABALIPURAM ROAD, KOTTIVAKKAM, CHENNAI-600041, TAMIL NADU Fax:+91 44 249 27127 Email: rotomechanical@vsnl.net MR. NARESH NANDA(PARTNER) AAR PEE INDUSTRIES B-4/60, SAFDARJUNG ENCLAVE NEW DELHI-110029 Fax:011-26196105, 26108578, 2550011, Email: aarpinrubber@hotmail.com; aarpeehoist@hotmail.com MR. RAVI KUMAR TRIKHA TRIKHA ACE STEEL FAB PVT LTD 45TH MILE STONE, VILL-PRITHLA, TEHSIL-PALWAL, MATHURA ROAD, FARIDABAD-121005, HARYANA Fax:911275270100/099 Email: trikharavi@hotmail.com MR. SAURABH AGARWAL(DIR) ACTION CONSTRUCTION EQUIPMENT PVT LTD PLOT-NO-7, IInd FLOOR, POCKET-H MARKET, SARITA VIHAR, NEW DELHI-110044 Fax:011-26953623, 26953626, 26953633, Email: marketing@ace-cranes.com MR. VIJAY AGGARWAL ACTION CONSTRUCTION LTD JAJRU ROAD, 25 MILE STONE, MATHURA ROAD, BALLABGARH-121004, 59 | P a g e
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HARYANA Fax:911292307171 Email: works@ace-cranes.com Mg. Director ALANKAR ENGINEERS ALANKAR, 8 HAZARESHWAR COLONY, HOSPITAL ROAD, UDAIPUR-313001, RAJASTHAN Fax:0294-2524733 Email: alanengg@sancharnet.in MR. SHYAM SUNDER SHARMA ANGIRA ENGINEERING PVT LTD 30, OLD RIICO INDUSTRIAL AREA, BY PASS ROAD, CHITTORGARH-312001, RAJASTHAN Fax:911472244627 Email: angiraeng@yahoo.co.in Mg. Director ANUPAM INDUSTRIES LTD 138, VIA ANAND, VITHAL UDYOGNAGAR-388121, GUJARAT Fax:02692-236118 Email: anupam@icenet.net SUSHIL C. HERI, DIRECTOR ARMSEL GROUP OF COMPANIES 25, KORAMANGALA INDUSTRIAL LAYOUT, HOSUR ROAD, BANGALORE-560095, KARNATAKA Fax:+91 80 5530439, 5535143 MR. PARMINDER SINGH ASHOKA MECHANICALS 3550, NEW JANTA NAGAR, GILL ROAD, OPP. P.S.E.B., LUDHIANA-141003, PUNJAB Fax:911615053850/2491775 Email: ashoka3550@yahoo.com MR. S. BHUPINDER SINGH SOHAL ASIAN CRANES & ELEVATORS OPP. ARORA PALACE CENEMA, GILL ROAD, LUDHIANA-141003, PUNJAB Fax:0161-2499756/2491054 60 | P a g e
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Email: info@asiancranes.com MR. SWARNENDU MAZUMDER ASSOCIATED AESBY INDUSTRIES PVT LTD 81, A.K. MUKHERJEE ROAD, KOLKATA-700090, WEST BENGAL Phone:913325313042/25313767 Email: aesby_industries@yahoo.co.in Mg. Director ATLAS CRANE SERVICE C-196, MAYA PURI, PHASE-II, NEW DELHI-110064 Phone:011-25400441 MR. C. S. BHOGAL AUTOMECH INDUSTRIES PVT LTD E-2, BULAND SHAHAR ROAD, INDL. AREA GHAZIABAD-201001, UTTAR PRADESH Fax:0120-2700250, 2701025, 2700889, (M) 9811082122, 9811082122, Email: automech@del3.vsnl.net.in Mg. Director AZAD JAR AND CROKERY HOUSE 196, AZAD MARKET, SADAR BAZAR NEW DELHI-110006 Phone:011-27778360 MR. NARESH BABBAR BABBAR WRECKER PVT LTD B-11, MAYAPURI INDUSTRIAL AREA, PHASE-1, NEW DELHI-110064 Fax:011-25132071, 28116026, 28116026, 28115071, 28117120 Email: admn@babbarwreckers.com MR. JAIN SANKAR BALAJI CRANE SERVICES 3, JAFFER SYRANG STREET CHENNAI-600001, TAMIL NADU Fax:044-2564213/25264214 Email: bcs@md4.vsnl.net.in Mg. Director BHAI SUNDAR DASS AND SONS CO 61 | P a g e
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4/23-B ASAF ALI ROAD, DARYA GANJ, NEW DELHI-110002 Fax:011-23277421, 23273302, 23270207, 23277836, 9810057575, Email: www.bhaitowercranes.com A. P. AMIN BOMBAY POWERLIFT PVT LTD GRACE PLAZA, 207-B WING, S. V. ROAD, JOGESHWARI (W) MUMBAI-400102, MAHARASHTRA Fax:022-26799494/26797146 SUDHA, DIRECTOR CENTURY FAB-TECH PVT LTD 487, K PALYA NEW EXTN., BASAVESWARNAGAR BANGALORE-560079, KARNATAKA Mobile:Fax:+91 80 3481546, 3481546 Email: cfabtech@satyam.net.in SPECTROMETERS MR. RAMESH DHIR DHIR SCIENTIFIC INDUSTRY 2762, TIMBER MARKET, AMBALA CANTT-133001, HARYANA Fax:Phone:911712632137/2643668 Email: dhir_kumar@rediffmail.com MR. S K SREEWASTAV EXCEL TECHNICAL SERVICES C-123,, B S ROAD, IND. AREA. GHAZIABAD, UTTAR PRADESH Fax:Phone:0120-2706288, Email: exceltechnicalltd@yahoo.co.in MR. M S ELECTRONICS (INDIA) P LTD 111, INDL. AREA-LL PANCHKULA-134113, HARYANA Phone:0172-2591307,2591048,2593955 Email: msei2000@yahoo.com
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Mg. Director MERCURY INTERNATIONAL A-16C-1 TODI UDYOG NGR, UTTAN ROAD, BHAYANDER(W) THANE-401101, MAHARASHTRA Fax:Phone:022-28192189 Email: mercuri@vsnl.net MR. P. D. PANT METAL POWER ANALYTICAL (I) PVT LTD C-46, RAJ INDUSTRIAL COMPLEX, MILITARY ROAD, ANDHERI (EAST), MUMBAI-400059, MAHARASHTRA Fax:Phone:912229203753, 29203756 Email: metpower@vsnl.com MR. GOPI NATH BANGERA MICRO DEVICES METROHM LTD NEW NO.13, OLD NO. 4/1, 1ST AVENUE, INDIRA NAGAR, ADYAR, CHENNAI-600020, TAMILNADU Fax:Phone:914424410444/24452726 Email: vgopis@yahoo.com MR. PUNEET NARANG MLSS SPECTRO STATION 1E/18, 2ND FLOOR, JHANDEWALAN EXTENSION, NEW DELHI-110055 Fax:Phone:911123624736/41540453/41540454 Email: rknarang@vsnl.com SREEDHAR, GENERAL MANAGER FINANCE PFEIFFER VACUUM INDIA LTD 25/5 NICHOLSON ROAD, TARBUND SECUNDERABAD-500009, ANDHRA PRADESH Fax:Phone:+91 40 277 50014,27750103 Email: pfeiffer@hd1.vsnl.net.in MR. MANOJ GUPTA SHREE RAM SCIENTIFIC WORKS 2765, TIMBER MARKET, AMBALA CANTT, HARYANA Fax:Phone:911712632875/2691004(R) 63 | P a g e
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Email: srsw@hotmail.com NILESH GANDHI, MANAGER ANALYTICAL PRODUCTS TOSHNIWAL INSTRUMENTS (INDIA) LTD 8, MOHATTA BHAVAN, OFF DR. E. MOSES ROAD, WORLI MUMBAI-400018, MAHARASHTRA Fax:Phone:+91 22 249 23979, +91 22 249 36062 Email: chemito@toshniwal.com Mg. Director VACUUM TECHNIQUES PVT LTD 36A AGS LAYOUT, MSR NAGAR BANGALORE-560054, KARNATAKA Fax:Phone:080-23601482/23601015 Email: vacuum@vsnl.com MR. RAJA NISHANT JAIN VINAY TRADING CO 3493, D C ROAD, AMBALA CANTT-133001, HARYANA Fax:Phone:911712642821/4009821 Email: info@vitcolab.com FLEXIBLE SHAFT GRINDERS MR. DEEPAK BILIMOIRA GALAXY ENGINEERING COMPANY K-1/16, G.I.D.C., ANTALIA, BILIMORA, DIST- NAVSARI, NAVSARI-396325, GUJARAT Fax:Phone:912634320246/280680 Email: galaxyeng_bilimoria@yahoo.com MR. A. G. GAWLI KAUSTUBH ENGINEERING WORKS 'KAUSTUBH', JANAKI NAGAR, OPP. OF MHADA SHOPPING CENTER, JULE SOLAPUR, SOLAPUR-413004, MAHARASHTRA Fax:Phone:912172301854 Email: kaustubhengg@sancharnet.in
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MR. JIGAR SHAH NIPPON ELECTRICAL INDUSTRIES 463/12, PANCHAYAT INDUSTRIAL AREA, NEAR SADVICHAR EYE HOSPITAL, G.I.D.C, NARODA, AHMEDABAD-382330, GUJARAT Fax:Phone:917922822750/22801888 Email: marketing@nipponpowertools.com JIGNESH MEHTA, PARTNER NIPPON POWER TOOLS 463/12, PANCHAYAT INDUSTRIAL AREA, NEAR SADVICHAR EYE HOSPITAL, G.I.D.C., NARODA, AHMEDABAD-382330, GUJARAT Mobile:Fax:Phone:+91 79 2822750, 2801888 Email: marketing@nipponpowertools.com MR. N. KALAISELVAN S K ENGINEERING 119, 31ST 'B' CRS., THILAK NAGAR, JAYANAGAR, BANGALORE-560041, KARNATAKA Fax:Phone:918026341984 Email: esskayeein@yahoo.co.in D. D. GAEKWAD, MD Z G EQUIPMENT PVT LTD 613, GIDC ESTATE, MAKARPURA VADODARA-390010, GUJARAT Fax:Phone:+91 265 642 910, +91 265 638 718, +91 265 642 174 WEIGHING MACHINES Mr J.J. Katawalla A A KATAWALLA 150, Janjikar Street Mumbai-400003, Maharashtra Phone: 022-23429757 Email: jkatawalla@yahoo.com Mr. R K Kalra AARKAY SALES CORPN. B-161, DDA Shed, Okhla Industrial Area, Phase-I 65 | P a g e
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New Delhi-110020 Phone:26818319, 26371054 Mob.: 9810472900 Bhavesh Joshi ACCURA SYSTEMS Oshiwara Industrial Center, 272-D, Link Road, Goregaon (W), Opp. Oshiwara Bus Depot Mumbai-400104, Maharashtra Phone: 022-28752671/2/3 Mg. Director ADAIR DUTT INSTRUMENTS PVT LTD 29-NA Block B, New Alipore Kolkata-700053, West Bengal Phone: 033-22488781 Email: adairdutt@vsnl.com Mr. Suman Mitra AFCOSET BALANCES 8/1, Chowringhee Lane Kolkata-700016, West Bengal Phone: 033-22451511/22445049/6298 Email: fidcal@cal2.vsnl.net.in Mrs. Gopi Nair AIRTEK MACHINERY LTD Atindra Centenary Bldgs., 14-B, R.N. Mukherjee Road Kolkata-700001, West Bengal Phone: 033-22104883 Mg. Director ALIEN TECHNOLOGY 29/110, Behind Charodia Police Chowky, Morarji Chowk, Bapunagar, Ahmedabad-380024, Gujarat Phone:+91 78 22776790, 22646205 Mr. M. Siva Shankaraan APOLLO SCALES No. 13, Aranganathan Subway Road, Cauvery Nagar, Saidapet 66 | P a g e
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Chennai-600015, Tamil Nadu Phone: 044-24322460 Mg. Director AMAN SCALES PVT LTD 14-A NEHRU GROUND, NIT FARIDABAD-121001, HARYANA Phone: 95129-2415463,,2415312, 2411862 Mg. Director AMCO EQUIPMENTS 1-B/6-A SIDDANA SINGH MARKET, PHAWRA SINGH CHOWK NIT FARIDABAD-121001, HARYANA Phone: 95129-2417698, 2280910 Aluminium Foil Printing/Laminating Machineries Mr. Azad R. Z - 73, Nursing Garden, Near Khyala Village New Delhi, Delhi - 110 018, India Telephone: +(91)-(11)-25981351 Mr. Amjad Khan (Managing Director) MOSCOW MACHINE TOOLS C-292, MUKUND NAGAR, Ghaziabad - 201001, Uttar Pradesh, India Ph: +919311553737 Aluminium Foil & Sheet Machineries Mr. Manager Hi-Tech International B-Wing, Flat 33, 3rd Floor, Chamunda Niwas, Tagore Road, Santacruz (West), Mumbai, Mumbai, Maharashtra - 400054 (India) Ph: +(91)-(22)-32964721 / 32964722 Fax: +(+91)-(22)-26614494 Mr. Robin Lee Shanghai Jingxiang Industrial (Group) Co., Ltd. NO.28 FEIYUN RD., LUOJING INDUSTRIAL ZONE, BAOSHAN DISTRICT, Shanghai - 200051, China Ph: 86-21-52065705 67 | P a g e
[EDPR/0966] (J.C.9601)
Mr. Gurjeet Singh JATINDRA ENGINEERING CORPORATION A-10/11, JHILMIL INDUSTRIAL ESTATE, Delhi - 110095, India Ph: 91-11-22110211/22572321/22582321/43724494 http://www.jatindraengineeringcorporation.com Mr. Anand Vaid VAID ENGINEERING INDUSTRIES 246, RAJDHANI ENCLAVE, PITAMPURA, Delhi - 110034, India Ph: 91-11-47019609/27189076/28353926 http://www.vaidengineering.com World Leading Machineries and Technology Provider( Supplied machineries to most of world leader in Aluminium Sheet and Foil) 1)IHI Metaltech Company LTD., Japan 2)SUMITOMO Light Metal 3)Mitsubishi Heavy Machineires, Ltd. IHI Metaltech had supplied almost all leading manufacturer of Foil and Sheet in the world. To know more about affordability of Caster technology in India you can contact any of this world leaders.
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SUPPLIERS OF RAW MATERIALS ALUMINIUM VIRGIN Pratek Khandelwal, MD BADRI PRASHAD MOHAN LAL 5230, Sadar Thana Road Delhi-110006 Phone: +91 11 236 74577 Email: pratcell@yahoo.com Vindo Mahipal, Director KAY BEE INDUSTRIAL ALLOYS PVT LTD Taher Mansion, 8, Bentick Street Kolkata-700001, West Bengal Phone: +91 33 221 06756, +91 33 221 03032 Email: kaybeeca@cal2.vsnl.net.in; kaybee@gems.vsnl.net.in; Sharad S. Dhurka, Director SSB ALLOYS & STEELS PVT LTD 414/416, IInd Floor, Maulana Azad Road, Girgoan Mumbai-400003, Maharashtra Phone: +91 22 238 60534, +91 22 238 21718 ALUMINIUM SCRAP Srinivasan Shekar, Owner MAHA POWER INDUSTRIAL TRADING CO 16-A/17, 10th Main, 3rd Block,, Sindhi Jayanagar, Bangalore-560011, Karnataka Phone: +91 80 223 4171, +91 80 227 5611 D. P. Chaya, Export Mgr MAJESTIK IMPEX PVT LTD 2/12, Palkan House, Tejpal Scheme, Road No. 5, Vileparle (E) Mumbai-400057, Maharashtra Phone: +91 22 282 03325,28361328 Email: majestik@vsnl.com Girish Deshpande, Export Executive 69 | P a g e
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MATAI IMPEX (INDIA) PVT LTD 101, Soni House, 34, Gulmohar Road No. 1, JVPD Scheme Mumbai-400049, Maharashtra Phone: +91 22 262 03334 Email: mataiin@bom7.vsnl.net.in; matai@vsnl.com Vijay Porwal, Director NICO EXTRUSIONS PVT LTD 12, Niraj Industrial Estate, Off Mahakali Caves Road, Andheri (E), Mumbai-400093, Maharashtra Phone: +91 22 269 38700 Mr. K. G. Shah SHREE KANCHAN METAL INDUSTRIES Phase-1, C-66/10, G.I.D.C., Nr. Old Telephone Exchange, Vatva Ahmedabad-382445, Gujarat Phone: 079-5830601 L. Agarwal, MD SRI KRISHNA ALUCAST (P) LTD 5, Donnappa Street, Park Town Chennai-600003, Tamil Nadu Phone: +91 44 25356121, 25356122 SILICONE Mangesh More, Export Mgr ACCURVA VALVES 5/267, Ashirwad Industrial Estate, Off. Ram Mandir Road, Goregaon (West) Mumbai-400104, Maharashtra Phone: +91 22 287 53612, +91 22 287 57512 Email: business@accurvavalves.com Mr. Harish AEROTECH (I) PVT LTD 70 | P a g e
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202, Shivam House, Karampura Comm. Complex New Delhi-110015 Phone: 011-25433375/25415491 Email: aerolformulations@aerolgroup.com N. V. Karunakar, Export Mgr AUROSRI INDUSTRIES 5/4, 1st Main Road, Kasturbanagar Adyar Chennai-600020, Tamil Nadu Phone: +91 44 244 15620 Email: santoshi@md3.vsnl.net.in Himanshu R. Kamani, Partner BHAVIK ENTERPRISES Suite No. 327, 3rd Floor, Bhaveshwar Arcade, L.B.S. Marg, Ghatkopar (W) Mumbai-400086, Maharashtra Phone: +91 22 250 02756 Email: berubber@vsnl.com Tejash Shah, CEO FLEXIBLE HOSE INDUSTRIES "Chatterjee International Centre", 33 A, Jawaharlal Nehru Road, Suit 11, 12th Floor Kolkata-700071, West Bengal Phone: +91 33 246 35264, +91 33 246 34938 Email: ventduct@vsnl.com Rooshad Patel, MD HI TECH RESISTORS PVT LTD Buty Compound, Mount Road Extension Nagpur-440001, Maharashtra Phone: +91 712 531 134 Email: info@htr-india.com Mg. Director PREMIER CONTROLS 17, Krishna Iyer Street, Nungambakkam 71 | P a g e
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Chennai-600034, Tamil Nadu Phone: 044-28258882/28274307 Email: premiercontrols@hotmail.com ZINC SUPPLIERS MR. YOGESH BHATNAGAR AAKASH INDUSTRIES NH-8, NAHARPUR,, OPP. ANAJ MANDI, BEHIND KRISHNA DHARAM KANTA, GURGAON, HARYANA Phone:0124-5034670, Email: aakash@junkmail.com MR. RITESH GARG AGARWAL METAL INDUSTRIES 5/500, B-7, SHAKTI NAGAR, ALIGARH-202001, UTTAR PRADESH Fax:915712521855/2523562/2511085 Email: ritesh124@sancharnet.in Mg. Director AMANI INDUSTRIES 814/10, BASAI ROAD, GURGAON, HARYANA Phone:0124-9810276773, ANIL BOHRA, PURCHASING MGR ANIL METAL CHEMCIAL & CORPORATION NO.1 NATRAJ, S.V ROAD MUMBAI-400054, MAHARASHTRA Mobile:Fax:+91 022 260 46144 Email: anant_anil@hotmail.com MR. HARSH VARDHAN KOTIYAL ANJALI TRADING COMPANY 2014, BELGIUM SQUARE, DELI GATE, SURAT-395002, GUJARAT Phone:912612663731/2478173(R) Email: kotiyalharsh58@rediffmail.com MR. AJAY GOEL ANYA ENTERPRISES EXIM (P) LTD A-122, MANGOLPURI INDL.AREA, 72 | P a g e
[EDPR/0966] (J.C.9601)
PHASE-II, GROUND FLOOR, NEW DELHI-110034 Fax:911127029491/32913158 Email: anya@bol.net.in MRS. SUKU NURIE & MR. ASIF NURIE (DIR) ATLANTA GLOBAL LTD 775, JASOLA VIHAR, SECTOR-7, NEW DELHI-110025 Fax:011-26952430, 9810541297 Email: afnh4@vsnl.net MR. SURENDRA B. SHINDE B L ELECTROPLATERS UDYOG NAGAR, OPP. INCOME TAX OFFICE, MALHAR TALKIES ROAD THANE, MAHARASHTRA Fax:022-25441823 MR. PRATEEK KHANDELWAL(MD) BADRI PRASHAD MOHAN LAL 5230, SADAR THANA ROAD DELHI-110006 Phone:011-23674577, 98114 29330 Email: pratcell@yahoo.com Mg. Director BALAMBIGA METAL FINISHERS # 830, S.R.S. ROAD, PEENYA BANGALORE-560048, KARNATAKA Phone:080-8399184 MR. PRADEEP KUMAR SHAW BHARAT SOLDER INDUSTRIES 46A, BIPLABI ANUKUL CHANDRA STREET KOLKATA-700072, WEST BENGAL Fax:033-22372262/22364319 MR. AMIT SINGH BINANI INDUSTRIES LTD 406, ASHOKA ESTATE, 24, BARAKHAMBA ROAD 73 | P a g e
[EDPR/0966] (J.C.9601)
NEW DELHI-110001 Fax:011-23314225, 23314854, Email: binaniml@vsnl.net M. AGARWAL, EXECUTIVE DIRECTOR CENTURY ALUMINIUM MANUFACTURING CO LTD 113, PARK STREET, PODDAR POINT, NORTH BLOCK, 3RD FLOOR KOLKATA-700016, WEST BENGAL Fax:+91 33 22291291, 22291164, +91 33 22297186 Email: admin@gncl-century.globalnet.ems.vsnl.net.in KANAKBHAI, PARTNER CLASSIC METAL 25, KANJI MANSION, 154, NANUBHAI DESAI ROAD MUMBAI-400004, MAHARASHTRA Mobile:Fax:+91 22 238 94121 Email: classicmetal@vsnl.com MR. SUBHASH SINGH DEEKCHHA ENTERPRISES D-1/37, 1ST FLOOR, SECTOR-16, ROHINI DELHI-110085 Phone:011-27898163, 27850870, 9810260041
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Page A- 1
PLANT ECONOMICS
Rated Plant capacity = 100.00 TONS./day of Sheet = 25000.00 TONS./annum of Sheet And = 5000.00 TONS/annum of Foil Basis No. of working days = 25 days/month = 300 days/annum No. of shifts = 3 per day One shift = 8 hours Currency - INR
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Page A- 2
LAND & BUILDING

1. Land Area required 4000 sq. mts. @ Rs.4000/- per sq. mts. 2. Production Shed in 2000 sq. mts. @ Rs. 2000/- per sq. mts. 3. Store for raw material and finished goods in 800 sq. mts. @ Rs. 2500/- per sq. mts. 4. Administrative Bldg. in 50 sq. mts. @ Rs. 7000/- per sq. mts. 5. Land development, Boundary wall gate & misc. construction expenses Rs. 1,60,00,000.00
Rs. 40,00,000.00
Rs. 20,00,000.00
Rs. 3,50,000.00
Rs. 16,00,000.00 -----------------------TOTAL Rs. 2,39,50,000.00 ------------------------
The above costs are subjected to change based on location, local construction cost and plant capacity. This information is based on data available to us. We do not take any responsibility.
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Page A- 3
PLANT & MACHINERY

1.Induction melting furnace with all accessories and Automatic voltage stabilizer 1 No. 2. E.O.T. Crane 7.5 MT Capacity 2 No. 3. Cooling Tower 1 No. 4. Water Pump pipeline etc. 5. Compressor 6. C. I. duplex moulds (L. S.) 7. Spectrometer 1 No. 8. Flexible Shaft Grinder 1 No. 9. Vibratory refractory sieve with driving gear and motor 1 No. 10. Water Trough with connection for cold water circulation 11. Platform type weighing machine 12. Foundry Tools Laddle & laddle holder tools, pipe & pipe fittings etc. 13. D. G. Set 300 KVA 14. Hot & Cold Rolling Mill 15. Finishing Mill 16 Annealing Equipments
Rs. 65,00,000.00 Rs. Rs. Rs. Rs. Rs. Rs. Rs. 22,00,000.00 7,00,000.00 3,50,000.00 2,25,000.00 4,00,000.00 18,00,000.00 1,00,000.00
Rs. 2,00,000.00 Rs. 45,000.00 Rs. 30,000.00
Rs. Rs. Rs. Rs. Rs.
12,00,000.00 14,00,000.00 8,00,00,000.00 1,00,00,000.00 50,00,000.00
-----------------------TOTAL Rs. 11,01,50,000.00 ------------------------
This information may change as it is based on Quotation available with us (not negotiated). It may also change based on technology availability in India. This information is based on data available to us. We do not take any responsibility
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Page A- 4
OTHER FIXED ASSETS

1. Office equipment, furniture plus other equipment & accessories 2. Installation costs for water, electricity, fuel etc. 3. Pre-operative & preliminary expenses 4. Technical Know-How & Consultancy 5. Misc. 6. Computer, Printer and Software 7. Goods Delivery Vehicle
Rs. 2,50,000.00 Rs. 6,00,000.00 Rs. 2,50,000.00 Rs. 3,50,000.00 Rs. 2,50,000.00 Rs. 2,00,000.00 Rs. 6,50,000.00 -----------------------TOTAL Rs. 25,50,000.00 ------------------------
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Page A- 5
FIXED CAPITAL
1. LAND & BUILDING 2. PLANT & MACHINERY 3. OTHER FIXED ASSETS Rs. 2,39,50,000.00 Rs. 11,01,50,000.00 Rs. 25,50,000.00 -----------------------TOTAL Rs.13,66,50,000.00
--------------------------
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Page A- 6
WORKING CAPITAL REQUIREMENT/MONTH

RAW MATERIALS 1. Commercial Grade pure 2500 tons. Aluminium Scrap @ Rs.110,000/- ton. 2. Consumable items viz. flux etc. 3. Alloying metals viz Chromium, Copper Magnesium, Manganese, Nickel, Silicon, & Zinc etc.
Rs. 27,50,00,000.00 Rs. 14,25,000.00
Rs. 1,52,00,000.00 -----------------------TOTAL Rs. 29,16,25,000.00 ------------------------
The above prices of Metal and its Scrape are subjected to change on Daily basis. This information is based on data available to us. We do not take any responsibility.
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Page A- 7
SALARY & WAGES / MONTH

1. 2. 3. 4. 5. 6. 7. 8. 9. Manager cum Technologist 1 No. Supervisors 3 No. Sales/Mktg. Executives 1 No. Accountant 1 No. Clerk/Typist 1 No. Skilled Workers 10 No. Semi-Skilled Workers 12 No. Helpers 16 No. Peon/Chowkidar 3 No. Rs. 45,000.00 Rs. 75,000.00 Rs. 15,000.00 Rs. 12,500.00 Rs. 10,000.00 Rs. 1,10,000.00 Rs. 96,000.00 Rs. 1,04,500.00 Rs. 18,600.00 -----------------------TOTAL Rs. 4,79,100.00 ------------------------
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Page A- 8
UTILITIES AND OVERHEADS

1. Power Consumption of 70000 Kwatt hrs @ Rs. 6.50 per Kwatt hr. 2. Water Consumption of 5000 KLs @ Rs. 4.00 per KL 3. Stationery, Postage, Telephone etc. 4. Conveyance & Transportation etc. 5. Publicity & Sales Promotion 6. Repairs & maintenance 7. Miscellaneous, Furnace oil etc.
Rs. 4,55,000.00 Rs. 20,000.00 Rs. 35,000.00 Rs. 2,50,000.00 Rs. 1,00,000.00 Rs. 50,000.00 Rs. 9,50,000.00 -----------------------TOTAL Rs. 18,60,000.00 ------------------------
Total load is 105 Kwatts
This unit price may change from state to state. Power consumption is based on machineries information we have it may change from machineries vendor to vendor. It may also change based on technology availability in India. This information is based on data available to us. We do not take any responsibility
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Page A- 9
TOTAL WORKING CAPITAL/MONTH
1. RAW MATERIAL 2. SALARY & WAGES 3. UTILITIES & OVERHEADS
Rs. 29,16,25,000.00 Rs. 4,79,100.00 Rs. 18,60,000.00 -----------------------TOTAL Rs. 29,39,64,100.00 ------------------------
1. WORKING CAPITAL FOR 1 MONTHS Rs. 29,39,64,100.00 2. MARGIN MONEY FOR W/C LOAN Rs. 7,34,91,025.00
COST OF PROJECT
TOTAL FIXED CAPITAL MARGIN MONEY Rs. 13,66,50,000.00 Rs. 7,34,91,025.00 -----------------------TOTAL Rs. 21,01,41,025.00 ------------------------
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Page A- 10
TOTAL CAPITAL INVESTMENT

TOTAL FIXED CAPITAL TOTAL WORKING CAPITAL FOR 1 MONTHS Rs. 21,01,41,025.00 Rs. 29,39,64,100.00 -----------------------TOTAL Rs. 50,41,05,125.00 ------------------------
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Page A- 11
COST OF PRODUCTION/ANNUM
1. Working Capital for 1 year Rs. 3,52,75,69,200.00 2. Interest @ 13.50% on T.C.I Rs. 6,80,54,191.00 3. Depreciation @ 10.00% on buildings Rs. 8,70,000.00 4. Depreciation @ 20.00% on Plant and Machinery Rs. 2,20,30,000.00 5. Depreciation @ 20.00% on office equipment & furnitures Rs. 50,000.00 -----------------------TOTAL Rs. 3,61,85,73,391.00 ------------------------
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Page A- 12
TURN OVER/ANNUM
1. By sale of 25000 Tons. Aluminium Sheet @ Rs. 120,000/- per Ton. 2. By sale of 5000 Tons. Aluminium Foil @ Rs. 150,000/- per Ton.
Rs. 3,00,00,00,000.00
Rs. 75,00,00,000.00 -----------------------TOTAL Rs. 3,75,00,00,000.00 ------------------------
PROFIT = RECEIPTS - COST OF PRODUCTION = 3,75,00,00,000.00 - 3,61,85,73,391.00 = 13,14,26,609.00
PROFIT SALES RATIO = Profit / Sales x 100 13,14,26,609.00 = ------------------------------ X 100 3,75,00,00,000.00
= 3.50%
RATE OF RETURN = Operating profit / T.C.I x 100 13,14,26,609.00 = ------------------------------ X 100 50,41,05,125.00
= 26.07 %
Prices of Sheet changes daily and Price of Foil depends on its gauge and use. Its prices changes daily. So, average price of R. 170/Kg of foil and Rs.120/Kg of Sheet is considered for calculation purpose. This information is based on data available to us. We do not take any responsibility
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Page A- 13
BREAK EVEN POINT (B.E.P)

Fixed Costs of the plant are as under 1. 2. 3. 4. Interests Depreciation 40.00% of salaries 40.00% of overheads Rs. 6,80,54,191.00 Rs. 2,29,50,000.00 Rs. 22,99,680.00 Rs. 89,28,000.00 -----------------------TOTAL Rs. 10,22,31,871.00 ------------------------
FIXED COSTS B.E.P. = ------------------------------ X 100 FIXED COSTS + PROFIT 10,22,31,871.00 ---------------------------------- X 100 10,22,31,871.00 + 13,14,26,609.00
= 43.75 %
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Page A- 14
RESOURCES FOR FINANCE
1. Term loans from Financial institutions ( 65.00 % of fixed capital ) at @13.50% p.a rate of interest 2. Bank loans for 3 months ( 65.00 % of working capital ) at @ 13.50% p.a rate of interest 3. Self raised capital from even funds & loans from close ones to meet the margin money needs at a @ 13.50% p.a rate of interest
Rs. 8,88,22,500.00
Rs. 19,10,76,665.00
Rs. 4,73,22,242.80 -------------------------TOTAL Rs. 22,42,05,960.00 --------------------------
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This project report has been prepared on the basis of information available with our Institute and Project Coordinators. The intention here is to provide preliminary information to the prospective entrepreneur. Prior to making a firm decision for investment in the project the entrepreneur must verify the various feasibility aspects together along with the addresses for the procurement of plant & machinery and raw materials independently. The informations supplied in this report is obtained from the reliable sources but it is not guaranteed, and the money once paid will not be refunded back in any case. Claims for incomprehensiveness of the project report will not be entertained and no legal action in this regard would be entertained in any case (Subject to Rajkot Jurisdiction only). Any matter relating to our standard points covered in the report may be modified with in 5 days time only from the date of delivery.
INDIAN PROJECT RESEARCH INSTITUTE | Project Coordinator : Mr. Abhishek
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Aluminium Foil & Sheet Project Report

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Aluminium Foil & Sheet Project Report

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ALUMINIUM FOIL & SHEET

INDIAN PROJECT RESEARCH INSTITUTE | Project Coordinator : Mr. Abhishek