PROJECT REPORT

ON

MANUFACTURING UNIT
OF

KLOCKNER LPG GAS CONVERTER KIT

FOR

MOTORCYCLES/ SCOOTERS
THREEWHEELERS
(4 Stroke and 2 Stroke)

Bajaj Pulsar 180 cc Average 165

KM

Honda Eterno Average 185 KM

LET US SHAKE HANDS

FOR GREEN REVELUTION
Introduction
KLOCKNER Gas Technology is a state of Art Technology and developed first time in the
world solely for small engines 50 cc to 375 cc air cooled, single cylinder 2 stroke as
well 4 stroke vehicles.
Sole Objective to introduce Klockner Gas Technology, is to declare liquid fuel (Petrol)

Carburetor based technology as obsolete, used presently world wide on 2 Wheelers and 3
wheelers.
Worlds scientific community and automobile engineers must discard this carburetor device,
as it is impractical for carburetor to mix air and petrol in accurate and in metered quantity to
suit the ever changing and variable engine requirements.
Carburetor technology has failed to control the uneven supply of petrol with the incoming air
stream to engine at various levels.
It is inbuilt and inherent draw back that in some circumstances the sucking air stream sucks
excess petrol at carburetor ventury, resulting in petrol wastage and pollution.
Now let us replace this redundant carburetor technology with new revolutionary klockner
gas technology, which promises: Cent % fuel efficiency.
With clean exhaust and Zero Pollution.
If this new technology is implemented with right spirit in India alone, on in-use
vehicles (Existing Vehicles) plus new vehicles added during the year.,
New KLOCKNER gas technology will save fuel worth Rs.200 crores per day.
or
73000 Crore rupees (Seven Kharab Thirty Arab Rupees) annually in foreign
exchange only.
Even more importantly this will prevent entry of 1.5 crore tons of carbon and NOx
pollutant from Air per day in India alone
Klockner Project will Drastically improve Air quality, crores of urban people suffering from Air
Born dieses will breathe in Fresh Air. (Which will help our urban citizens to breathe in fresh
Air), even lot more saving will be on a/c of engine life & maintenance.

MARKET POTENTIAL
To date No Proven Gas Technology available world wide to run two wheelers & single
cylinder small engine on LPG.
Klockner LPG converter provides complete solution and 110% performance of petrol
engine on Auto LPG Fuel.
In India alone we have an existing population of 90 million 2 wheelers
And every year another 9 Million new 2 wheelers are added to this existing population.
If every year 10% of this vehicle population if converted to LPG system then in India alone
we have an existing market of kits worth 4000/- crores Rupees.
Converter kits can be supplied as OEM to 2 wheeler giants (After all types of Govt. Approval
and certification).
Tremendous export potential, as there is a growing demand of LPG based products in ASIAN
countries like Philippine, Indonesia, Malaysia etc.,

Market Viability
LPG as Auto fuel is gaining popularity day by day. LPG dispensing Units/ Pumps are opening
up in all major cities of the country in another 2 years time another additional 20new cities
will be having LPG Pumps.
Major car manufacturers like Maruti Suzuki , GM etc., are already offering cars on only LPG
Fuel.
As a low polluting, LPG Auto Fuel is on promotional list of Govt.
Performance of Klockner kit on 4 Stroke Motorcycle/ Scooter

Petrol Km /
Ltr

Rs. / Km.

LPG Km./Ltr.

Rs. /Km.

100 cc to 125
cc M/Cycles

60 Km/ Ltr.

Rs.0.75 /Km

72 Km/ Ltr

* Rs.0.37
/Km

350 cc
M/Cycle
( Bullet )

40 Km/Ltr

Rs.1.13 /Km

50 Km/Ltr

Rs.0.53/Km

Remarks
*
*
*
*

LPG/Ltr. Cost
calculated on
commercial/Auto
LPG Rates

- Do-

Fuel Saved 50% to 75%.

ALL KLOCKNER GAS MODELS FOLLOWS THIS THUMB RULE FOR GAS AVERAGE:
2 Stroke Engines - * 4 Times The Petrol Average.
4 Stroke Engines - 3.5 Times The Petrol Average.
(LPG Cost :- all calculated on domestic LPG Rates)
LPG is a clean burning fuel and reduces clogging of spark plug as well as carburetor and
piston block, whereby you save on maintenance cost.
PROJECT AT A GLANCE

UNIT CAPACITY

1,00,000 Units Per Annum. (8 hours shift)

Total Investment

20 Crores

Plant & Machinery

6 Crores

Land Building

3.7 Crores

Power Required

300 K. Watt

Utility & Allied Services Air Circulation

(Like Air Ducts/Blowers, Fan, coolers
etc) Lighting, Water Supply, Storage
and disposal Water Cooler Drainage
and sewerage Canteen Garbage Shed
and disposal system Scrap Collection
& disposal system Workshop
Cleaning System

0.5 Crore

Govt. Approvals

1 Crore

5 Crores

90 Nos. (Semi-skilled/Skilled Workers)

Inclusive of Engineers Management Staff
& Workers..

Patent of all systems

Approval by explosive Nagpur
Approval by ARAI, Pune

Marketing Budget Ist year

Manpower required

Unit Cost of Production Approx.

8 hour shift

16 hour shift

24 hour shift

Product Capacity

1,00,000 Unit / Annum 2,00,000 Unit / Annum 3,00,000 Unit / Annum

Unit Cost of Prod.

Rs. 2500 / Unit

Rs. 2,000 / Unit

Rs. 1800 / Unit

Pay back period

: The pay back period for the project shall be one year

Gestation period

: Six to Eight Months

Working Capital
Requirement

Consultancy Charges

: 0.5 Crore

PP Expanses

: 0.3 Crore

Unit Ex- Factory Price

: Rs.3000 per unit.

Yearly Turn Over

: 60 Crores (Double shift basis)

Net Profit before taxes

: 20 Crores.

3 Crores (0.3 Crore Promoters + Balance Financial

Institution).

DESIRED LOCATION
We suggest that the above plant be installed in the state of Uttarakhand or Himachal
Pradesh in order to avail the following fiscal incentives.

Excise holiday for 10 Years.

Income Tax holiday for 5 Years. & thereafter 30% rebate for next 5 Years.
15% Capital investment subsidy subject to a maximum limit of Rs. 30Lacs
(This amount would cover all PP expanses of initial setting up of plant).
Marketing NOTES
1.
2.
3.

After initial approvals from explosives dept. Nagpur & ARAI, Pune. Following marketing
practices may be adopted: a. Electronic Media.(TV Channels / News Channel etc.,)
b. Print Media.(All National Dailies & Regional Papers)
c. Demo Vehicles for live demos
Participation at all local trade fares with live demo.

Glimpses: Klockner gas Converter technology

It is impossible to have successful running of 2 Wheelers, specially new generation 4 stroke
motorcycles on LPG gas fuel with a help of High Pressure Italian Gas Technology, which is
currently in use to run car and heavy automobiles all over world for last 25 years.

Activa

Exploded View Activa Rear Fitting

Bajaj Chetak

Let us have Arial view on Klockner Gas Technology

Klockner gas technology is a amalgamation of a seven new principles and technologies,
which we have discovered first time in the world and applied for successfully running of all

types of 2 wheelers on LPG Fuel. It is not the all, bike fitted with Klockner gas kit system
beats petrol run original Models in terms of power developed, cold starting, fuel efficiency,
pick up, pollution, maintenance and engine life.
a) EMR Single kick starting technology
This system ensures first kick-start of engine without touching the Accelerator. In this
starting technique Air& Fuel are pre mixed in explosive ratio & fed directly to intake manifold
facilitating instant starting.
b) RVO Power Enhancer Technology
This supersaver Reed Valve Operated device
specially developed to work in tandem with
the gassifire does not allow any fuel wastage
by the kit and enhances the power output of
the engine, for example:- if an engine has a
top speed of 100 Km./hour on petrol then on
klockner gas system with this device, ensures
that the engine will give a top speed of 105
Km/hour.
Emitting pollution levels also comes to near
zero.

Power Enhancer Device

c) Low Pressure Klockner Gassifire

All klockner gas system works on lowpressure systems i.e., Gas cylinder by design,
supplies gas fuel at a pressure as low as 0.5
PSI.
KLOCKNER Gassifire is a single stage suction
based, twin diaphragm operated precision gas
to gas control valve, specially designed to run
air cooled single cylinder engines 50 cc to 375
cc 4 stroke as well 2 stroke

Klockner Gassfire
d) MVLPO Gas Container

Gas Containers, Capacities 2.5 kg, 2.2 kg & 2 kg

Gas Meter

MVLPO Gas Container is a specially designed system for safe handling & storage of Liquid Gas.
MVLPO Gas cylinder are available of capacities 2.5 Kg. (4 Ltr. LPG capacity), 2.2 Kg (3.52 Ltr.
LPG capacity) having inbuilt functions like a) Fuel level meter which indicates gas in Kg scale b)
Excess pressure release valve / safety valve c) Filler valve (To fill gas from Auto LPG Station/
dispensing units) d) Low pressure gas Output at 0.5 PSI (with double locking valve) installed
with a low pressure rugged output regulator, with flow adjustment facility.
(ALL THESE SYSTEMS ARE DESIGNED TO WITH STAND 5 TIMES THE WORKING PRESSURE)
e) Oil And Dirt Separator
All klockner kits consist of a special filtration system, which enhances the performance of the
total system. Protect system from all metallic impurities / rust particle in fuel., Increases the
life of the gas cylinder and the total system.
It Prevents any fuel Line choking, Meter Jamming etc. This system also separates the wax
(Scent chemical: - ethyl me captor, C2H5SH) - out of gas hence increasing the life of gassfire
components manifolds (no periodic cleaning) of vaporizer necessary as in case of all other
vapourisers available for cars.
f) SSJ Ideal Speed control
It is impractical to have constant ideal running of a single cylinder 4 stroke engine with the
help of Diaphragm Based Vaporizer, specially in cold conditions. To overcome this problem
Solenoid based slow jet speed control technique has been developed.

g) i) Electronic PWR 2-T oil system

Electronic pulse width regulation oil system is a

specially developed 2-T Oil Pump meant for
smooth supply of 2-T Oil to 2 Stroke engine and it
ensures supply of 2T-Oil in proportion to engine
RPM. It enhances engine life & performance.

Power Based Electronic 2-T Oil Pump

ii) GTP Mechanical Oil Pump

This is a mechanical vacuum operated 2T-Oil
Pump and is a alternate, direct replacement to
electronic PWR 2T oil system. Safest gas system
of the world.
h) All klockner LPG Converter kits function on
lean burn system and operates at extremely low
pressure. Thereby maximizing fuel efficiency and
overall system safety. Gassifire releases gas only
when the piston of the vehicle generates a stroke,
as soon as engines stops for any reason the gas
supply to engine cuts of automatically.
Mech. Oil Pump

OTHER APPLICATIONS : A BRIEF VIEW

Klockner gas technology finds endless applications
and is extremely useful for applications like:
a. Outboard engines / Fishing Boats / Speed
Boats etc.
b. Petrol and kerosene run multipurpose
engines used for miscellaneous applications.
c. Petrol and kerosene run water pump sets.
d. Petrol and kerosene run Portable Generators unto 500
VA to 7 KVA

Yamaha Water Pump 3" x 3"

Honda Elemax 7000

Yamaha LG 700 K

Honda EM-650

Yamaha LG 2000

Honda E-650 K

Yamaha LG 2800

Popular Models of Portable Generator running on Klockner Gas System

Constitution of Klockner LPG Converter kits: -

Klockner LPG Converter kit consists of the following Sub-Assys: a. Dikki /Housing
b. Bracket Assy
c. Drainer Assy
d. Gassifie Assy
e. Solenoid
f.

Control Circuit & Wiring

g. Container / Cylinder Assy

h. Regulator Assy
i.
j.

Pipe Assy. / Cylinder Belt

Nozzle / Ventury Assy

k. Gas Filling Attachment Assy

l.

RVO Power Enhancer

m.

Electronic PWR 2T-Oil

System

n. GTP Mechanical Oil Pump

BRIEF SUMMERY OF PROJECT

Total Area required

Total Covered Area
Power required & Distributions
Manpower required
Unit Cost of Production

5000 Sq /Mtrs.
2500 Sq/Mtrs.
300 K.Watt
90 Nos. (Semi-skilled/Skilled Workers)
Inclusive of Engineers Management
Staff & Workers.
2000 Rs./Unit ( at 50% capacity
utilization i.e. TWO eight hour shifts).

Office Building
(Double Story)
200 Sq/Mtrs.
Guest House
300 Sq/Mtrs.
Utility & Allied Services
Air Circulation ( Like Air
Ducts/Blowers,
Fan, coolers etc) Lighting, Water
Supply, Storage and disposal Water
Cooler Drainage and sewerage
Canteen Garbage Shed and disposal
system Scrap Collection & disposal
system Workshop Cleaning System
Provisions for Govt. Approvals
Patent of all systems
Approval by explosive Nagpur
Approval by ARAI, Pune
Air Compressor (2 Stage
Compressor)
1 No
(500 PSI Capacity)
Air Compressor (100 PSI Capacity)
1 No
(100 Cubic Meter Storage capacity)
Generator Set (20 KVA)
1 No
(To maintain essential services)
Security and Surveillance equipment
Computers with Video Conferencing
facility
Through Broad Band Internet
Connection
Computer Plant Management
(Including accounts

INR (Rs.)
Lacs
100
190
30

25
25
50

100

2
10
1
3
7

& Stores
Furniture Fixture
Material Handling system
(MS cage bins, hand pallets, trolleys,
forklift
Electric hoists (5 ton capacity)
Stores
Raw materials stores,
Finished products stores
Tool crib ( Production), Tool crib
(Machine Maintenance), Packing Area
Conveyer Line( for 3 to 4 Assy.
Systems)
(As per design)
Assy. Tools and hand tools
Pneumatic Tools
Sheet Metal Press Shop ( 18 Nos.)
(Presses from 5 ton to 50 ton
capacity)
Sheet Cutter 2 Nos.
Semi Automatic Electrostatic Paint
Shop
Plant & Machinery
Maintenance Tool Room machinery
Special Purpose Machines
Welding Machines 15 Sets Tig
Welding with special motorized
welding fixtures etc., Automatic
Winding Machine & Varnishing Plant
Packaging Machine & Dies
G N MOTa
QC Jigs & fixtures
QC Test benches
All type of Press Tools and Dies
Forging Tool and dies
Rubber Molding Dies
Plastic Molding Dies
Special Pneumatic Tool Holders
CONSULTANCY CHARGES
WORKING CAPITAL REQUIREMENT
A) Three weeks raw material of local
purchase,

10
75

15
5
10
75
5

200
8
50
3
10
15
15
60
8
3
3
1
50
300

Publicity & Advertisement (Ist Year)

PP Expanses
Total Project
TOTAL YEARLY TURNOVER
RECOMMENDED EX FACTORY PRICE
RECOMMENDED CUSTOMER PRICE

500
30
2000 Lacs
60 Crore Per annum
3000 Rs/ Unit
4000 Rs. PER UNIT

UNIT COST OF PRODUCTION

8 Hour Shift

16 Hour Shift

24 Hour Shift

Production Capacity

100,000 Unit P.
Annum

200,000 Unit P.
Annum

300,000 Unit P.
Annum

Unit Cost of
Production

2500 Rs./ Unit

2000 Rs./ Unit

1800 Rs./ Unit

TOTAL PROJECT COST

20 Crores

ANNEXURE-I
List of In-hose production items
1)
2)
3)
4)
5)
6)
7)
8)
9)

Dickey / Kit hosing

Bracket Assy
Drainer Assy
Gassifire Assy
Solenoid
Control Circuit & wiring
Cylinder / Container
Regulator Assy
Testing, Assy. and Packing

ANNEXURE-II
Vender Components
1)
2)
3)
4)
5)

Dikki Locks
Diaphragms Gassifire
Diaphragm Regulator
Traub Items for cylinders, Gassifire and regulator
Meter Assy. (Inclusive of Brass forging base plate)

6)
7)
8)
9)
10
)
11
)

Solenoid core and bobbin

All Type of Special Rubber O Ring Washers and components
Filler Valve
Safety Release Valves
Economizer
Gas filling Attachment Assy

LIST OF LOCAL PURCHASE ITEMS

a) Pipe Roll
b) Hinges
c) Fasteners etc.,
LIST OF RAW MATERIALS
a) MS Sheet
b) Copper Wire
c) Packing Material etc.,
STORE CONSUMABLES
a) Welding Wire & Welding Rods
b) Carbon dioxide Gas
c) Paints, Primer & Thinner
d) Varnish
e) Cutting Tools etc.,
Klockner gas technology is latest R & D work by professionals of Research &
Analysis Alternate Energy Resources. Hence it is strongly recommended before
going for bulk productions, Entering party must obtain patent & legal rights so as
to safeguard his business interest and monopolized market potential.
By:
Gas Tech Electronic Products (P) Ltd.
28, Mohini Road, Dehradun-248001
Ph. 0135-2672540
e-mail : info@gastechproducts.com
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