Copper and Copper Products

Copper is a very special metal for industrial applications and has been mined for centuries. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is rather soft and malleable, and a freshly-exposed surface has a pinkish or peachy color. It is used as a thermal conductor, an electrical conductor, a building material, and a constituent of various metal alloys.Other copper minerals are far more economical to mine and purify into metallic copper that is used for wiring, electrical components, pennies and other coins, tubing and many other applications.Copper metal and alloys products have been used for thousands of years.

Copper owing to its properties such as electrical conductivity, corrosion resistance, ductility, malleability and rigidity finds wide applications in various fields. Specific applications of copper include power cables and wires, jelly filled cables, building wires, air conditioning and refrigeration tubings in telecom, power, construction, transportation, handicrafts, engineering, consumer durable, defence. The electrical industry claims a share of about 26%. The electronics and communications take another 30% share. With building construction (9%) and transportation (8%) added, the cumulative rises to about three-fourths. The other consuming sectors are engineering process and general (9%) and consumer durables (6%). Defence is also a substantial user. Another important consumer is handicrafts which are reported to consume close to 12% of copper in India. Apart from the primary copper production, scrap copper supply is placed at around 170,000 TPA. This is made up of defence cartridge brass scrap (17%); scrap from forging, fabrication, redrawing and machining (31%); old winding scrap (13%); copper cable scrap from electricity and telephone sector (12%); and cable units (9%).

The Indian copper industry comprises 3% on the world copper map. The domestic market is in a surplus position now with the production towards the end of the current financial year is likely to go up to 947500 tonnes as against the demand of roughly 5 lakh tonnes. The demand supply imbalance is unlikely to deteriorate further, as the ongoing boost in the country's infrastructure is expected to appreciate the demand. The unorganized sector players are also likely to contribute, however, about 1.5 – 2 lakh tonnes, thus; taking the total production of beyond one million tonnes towards the end of the current fiscal year. Major of LME-grade copper produced by the private sector majors is exported. HCL, however, has been dominating in the domestic market. SIIL, a part of Vedanta Resources, a London listed $3 billion, pioneered the manufacturing of continuous cast copper rods in India and established India’s largest copper smelting and refining plant for production of world class refined copper.  India’s copper demand will likely grow by at least 7% in financial year 2010-11, fed by power sector, while demand from real estate and construction remains weak, according to industry analyst. In India the users segment such as winding wire, power cables, transformers industry and continued increased export of downstream products supporting higher demand.

Sterlite Industries, Hindalco and Hindustan Copper are the top three producers of the metal in the domestic market.

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Enameled Copper Wire

Enameled wire is an insulated wire used in winding of armatures in transformers, switch gears and other electrical equipments. When connected to the main supply a magnetic field is developed around the enameled wire coil and it helps to the conversion of electrical energy into mechanical energy as case of motors. With the industrial development and power generation its demand is growing very fast. At present the finer gauges are being imported therefore there is scope for import substitute as well as for export to USA, Australia, Europe and far East. The demand of enameled copper wires is increasing tremendously due to its large consumption of end users industries. You can invest in this project.
Plant capacity: 500 Kgs/DayPlant & machinery: Rs. 22 Lakhs
Working capital: Rs. 52.0 LakhsT.C.I: Rs. 114 Lakhs
Return: 37.43%Break even: 46.95%
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Copper Sulphate From Copper Scrap, Copper Ash, Industrial Waste Containing Copper Content

Copper Sulphate is blue crystalline granule or powdery white when dehydrated and has a nauseous metallic taste. It is manufactured by the reaction of dilute sulphuric acid on the copper scrap, copper waste in presence of oxygen. It is used in agriculture, leather industry, electric batteries, ore floatation etc. There is about 3% growth rate per annum. The new comer can well venture in this field.
Plant capacity: 600 MT/Annum Plant & machinery: Rs. 69 Lakhs
Working capital: -T.C.I: Cost of Project Rs. 205 Lakhs
Return: 37.00%Break even: 63.00%
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COPPER POWDER BY ELECTROLYTIC PROCESS

The principal methods for producing copper powder is electrolytic deposition at high current densities and the atomization of molten metal. Copper powder is also formed by cementation or by pressured precipitation from acqueous solutions, but such precipitates are of little commercial interest. There is no copper powder manufacturers. It is products like copper utensils, electrodes, copper wires etc. These residues on size screening separate out the powder. As such copper powder is imported from European countries for putting up copper powder unit by electrolytic process.
Plant capacity: 150 MT/DayPlant & machinery: 45 Lakhs
Working capital: -T.C.I: 158 Lakhs
Return: 39.00%Break even: 63.00%
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Power Cable

Electrical power cables used for transmission and distribution purposes consist of conductors stranded from plain high conductively annealed copper wires insulated with oil impregnated paper tapes. Under ground construction is necessitated in the more density built up portions of cities by the heavy transformers and lines required and by the multiplication of service connections to buildings. PVC coated cables and wires are extensively used in all electrical linings, domestic lightings and all other purposes. According to the present policy of the India Government, this time, PVC coating on electric cables and wire is exclusively reserved for development in small scale sector or in the cottage industries. The demand for PVC coating electrical wires is increasing at a rapid rate. There is a bright scope for starting new units in this field.
Plant capacity: 2050 MT Aluminium Power Cable/Annum 350 MT Copper Power Cable/AnnumPlant & machinery: Rs. 80 Lakhs
Working capital: -T.C.I: Cost of Project Rs. 305 Lakhs
Return: 45.00%Break even: 60.00%
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COPPER FLATS AND COPPER TUBES

Copper is the most commonly used architectural metal now-a-days. Copper plays an essential role in the modern building. From recycled cladding and roofing systems, to high-tech plumbing and heating systems using the tube and fittings which are manufactured from recycled copper. Copper is a key component of many energy saving technologies. Copper is specified for use in most commercial plumbing, and is used extensively as a tubing material in HVAC systems. Copper and copper alloys constitute one of the major groups of commercial metals. They are widely used because of their excellent electrical and thermal conductivities, outstanding corrosion resistance, and ease in fabrication. In a vast country like India with large population, and positive sign of continued growth of economy and industrial activity, encouraging demand growth rate for copper and copper alloy tubes can be expected. The sectoral growth percent will vary from very high to medium. But overall the scenario appears to be bright. And we can say that the new entrepreneur can well venture into this field.
Plant capacity: 12 MT/dayPlant & machinery: 198 Lakhs
Working capital: -T.C.I: Cost of Project : 567 Lakhs
Return: 47.00%Break even: 56.00%
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Inner Grooved Copper Tube

Ongoing rise of Air Conditioners and Refrigerators in the market and production in GCC and other part of the world and Heat Transfer Systems in engineering industries and automobile sectors all over the world, makes Copper tubes an essential and unmatched engineering material as Copper possesses superior heat transfer properties with excellent corrosion resistant. Seamless Copper Tubes meeting the specification requirements of ASTM B68, ASTM B280 and JIS H3300 for ACR applications are in a commanding and challenging position in the market. Conventional technology and tube mills are getting outdated as superior new generation software based tube mills have already shaped up and proved their efficiency and quality in production in this technology era and provides platform for producing superior quality tubes. As old companies with conventional machines struggle for their survival, as Quality and Cost are the prime concern governing the market and business world today, new ventures are shaping up and establishing bases to conquer the market. The market: Market analysis in the GCC bloc shows a positive growth and potential market segment exists within GCC countries. Exports to Asian and Middle East countries seems to be bright as exports from GCC incur lower freight charges, which enhances reduction in cost over material procurement at customers end as compared with imports from Japan or European countries. Market Demand Analysis Having considered the project concept, production process and technology, it deems fit to project the market demand for copper hollows. Copper hollows are used in three distinct types of air conditioning systems, viz. i. Window A/Cs ii. Split units iii. Central air conditioning systems Again, the Indian and GCC market for air conditioning copper tubes, two segments are conceptualized namely, a) ACR Tubes used in the manufacture of A/Cs systems – Primary users b) Service tubes for field used in contractual jobs – Secondary users UAE has two manufacturers of A/C units as detailed below: i. Sharjah and Kuwait Manufacturing Co. Ltd, Sharjah ii. French Gulf A/C & Refrigeration Co., Jebel Ali And one more company in the service field M/s. Juma Al Majid trading and contracting company. In Qatar several contractors are operating in the service fields and no primary user is being identified and yet to be ascertained the primary users of Copper Tubing. Saudi has two primary potential users SAMCO and AL ZAMIL and few contractors in the service field. Kuwait market details are not clear and the market position is yet to be studied. Though A/C manufacturers are not known, contracting field operation in the field is sure and a considerable quantum of copper hollows must be in marketable lead. There are two A/C manufacturers in Bahrain: i. Awal Products W.L.C., Manama ii. Al Khaja Establishment & Factories, Manama The sources of supply of seamless copper tubes are from Japan, USA, Finland and Belgium previously and a meager market segment is captured by east Asian countries. The overall size of market in GCC bloc at present is increased to 106000 MT according to trading information, magazines and ministerial reports and the market base getting expanded as A/C manufacturers are boosting up their operation in GCC region as a supply source to many middle east countries. Besides, market band can be established in Asian countries and in Europe as the market demand is high and the present source is only Japan and once the quality seal is established, can out weigh the Japan market as supplies from GCC fetch considerable gain to the customers on freight charges. Why Copper tube Plant to be need to set up in India First Inner groove Copper Tube Plant INDIA and get pioneer status Ultra Modern Port Facilities Modern International Airports Accessibility to the Customers Best Government Policies to promote Hi-tech Industries Relief from import duty exemption on imports of machinery and raw material for some period. Soft Loans with low interest rates. Fully serviced Industrial Estates/Free Trade Zone across the country offers investors a comprehensive infrastructure to set up a manufacturing base. An Excellent Urban Network of Roads & Waterways to most Middle East Countries and Europe. Better Information Technology Set up Middle East, South Africa, USA, some European countries and India are importing Copper tubes from China, Japan and South East Asian Countries. If we manufacture these Copper Tubes either in India, we can capture these markets easily since we are nearby and the Quality and Price are so attractive.
Plant capacity: 12000 TPAPlant & machinery: -
Working capital: -T.C.I: 65 Crores
Return: N/ABreak even: N/A
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COPPER INGOT / COPPER ASH FROM COPPER ORE

Copper is the perfect material for recycling. It is valuable, easy to identify, easy to clean, heavy and can be much use to foundries & other non-ferrous industries as scrap. It has many important alloys e.g. bronze and brass. Copper being very versatile metal, it encompasses a very wide field of applications which comprise electric wiring, switches, plumbing, heating, roofing and building construction, chemical and pharmaceutical machinery etc. The Indian copper industry saw a phenomenal boost in production and consumption. The production capacity has been further increased in phases to 5,00,000 tonnes. The company is also aggressively developing value-enhancing strategies for its existing product. Indias strong economic growth and key priority for the power sector, which is major consumer of copper, will support high demand and price in the near term. The Indian copper industry comprises three percent on the world copper map. It is a lucrative trade with bright future prospects.
Plant capacity: 3000 MT / AnnumPlant & machinery: 279 Lakh
Working capital: -T.C.I: Cost of Project : 684 Lakh
Return: 46.00%Break even: 45.00%
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COPPER WIRE DRAWING (From Higher Size to Very Thin Size Used in Electrical Cables)

Copper wire is an essential material for electrical cables, motor and transformer winding. It is available in different gauges. The gauge of the copper wire depends upon the winding required for the specific motor or transformer. On the basis of high conductivity, strength and ductility, copper wires are adopted as the best known economical material for such purposes. Copper is used mainly in the electrical industry for manufacturing parts of electrical apparatus, bus bars, wires etc. Another reason for its wide use is that the copper has resistance to atmospheric corrosion because of the formation of uniform layer of oxide on the surface of the metal. Besides these factors, copper has good mechanical properties viz. good of copper conductor wire is so high in India that despite a fair increase in installed capacity and actual productions of the units, import is continuing. Thus, some more new units need to enter the field.
Plant capacity: 500 Kg. / DayPlant & machinery: 68 Lakhs
Working capital: -T.C.I: Cost of Project : 167 Lakhs
Return: 43.00%Break even: 46.00%
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COPPER WIRE DRAWING (From Higher Size To Very Thin Size Used In Electrical Cables)

Copper wire is an essential material for electrical cables and motor and transformer winding. Copper wire is available in different gauges (42 gauges to 18 gauges). The gauge of the copper wire depends upon the winding required for the specific motor or transformer. There is a heavy market for copper wire in motor and transformer manufacture and the copper is also used in rewinding of motors and transformers. Whatever the motor may be the winding of copper wire is done. On the basis of high conductivity, strength and ductility, copper wires are adopted as the best known economical material for such purposes. Copper is used mainly in the electrical industry for manufacturing parts of electrical apparatus, bus bars, wire etc. Copper is not very ductile at temperature from 250 to 6000C and cannot be forged or stamped at temperatures above 8000C, due to its high brittleness. Pure copper is very seldom forged or stamped and usually only its alloys bronze and brass are subjected to forging and pressing. Wire is made by cold drawing hot-rolled wire/rod through one or more dies, to decrease its size and increase the physical properties. The wire rod about 7/32" (6mm) in diameter is rolled from a single billet and cleaned in an acid bath to remove scale rust and coating. The coating is applied to prevent oxidation, neutralize any remaining acid and to act as a lubricant or a coasting to which a later applied lubricant may cling. There is a very good scope for this product and new entrepreneurs should venture into this field. Few Indian Major Players are as under: Metal Aids India, Mumbai Nissan Copper Limited Samitan Electropowers (P) Limited S. M. Enterprises, New Delhi Niki Cables Industries Bharat Insulation Company (India) Ltd Elecon Conductors Limited Saru Concast Alloys Pvt. Ltd. GTB Indo Exports Shree Nursingsahay Mudungopal Engineers Private Limited Metro Steel Corporation Optiflex Industries Nana Udyog Saru Copper Alloy Semis (P) Ltd. Manhar Metal Supply Corporation Harness Techniques(i) Pvt Ltd National Wire Industries Metal Aids India Indo German Wire Screen Co. A. P. S. Enterprises Oasis Electronics Max Engineering and Marketing Company KMA Electricals (P) Ltd. Sharpwire Industries (India) Private Limited Kawa Machine Tools Sdn Bhd Dali Electronics Vijay Trading Corporation
Plant capacity: 150 MT/AnnumPlant & machinery: 69 Lakhs
Working capital: -T.C.I: 167 Lakhs
Return: 45.00%Break even: 42.00%
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COPPER ROD CASTING, WIRE DRAWING AND ENAMELLING

Copper wire is an essential material for electrical cables, motors and transformer winding. Copper wire is available in different gauges. The gauge of the copper wire depends upon the winding required for the specific motor or transformer. There is huge demand of copper wire in electrical industry such as in motor and transformer manufacturing and rewinding. On the basis of high conductivity, strength and ductility copper wire are adopted as the best known economical material for such applications. As a result of increasing demand and wide applications number of new units have been established and existing units have undergone expansions and for increasing productions in order to cater the ever growing demand. However, the demand of copper conductor wire is so high in India that despite a fair increase in installed capacity and actual productions of units, import is continuing. Thus, there is a good potential for new entrepreneurs. Few Indian Major Players are as under: Bhagyanagar Metals Ltd. Bharat Insulation Co. (India) Ltd. C M I Ltd. Dharmadeep Powerdive Inds. Ltd. G K Winding Wires Ltd. Ganga Electrocast Ltd. Globus Corpooration Ltd. Hindustan Transmission Products Ltd. Indo American Electricals Ltd. M P Telelinks Ltd. Mardia Samyoung Capillary Tubes Co. Ltd. Paramount Communications Ltd. Patron Industries Pvt. Ltd. Powerflow Ltd. Precision Wires India Ltd. Ram Ratna Wires Ltd. Robot Systems Pvt. Ltd. Salzer Electronics Ltd. Shakti Insulated Wires Pvt. Ltd. Shalimar Wires Industries Ltd. Supreme Conductors Ltd. Translam Ltd. Vardhaman Wires & Polymers Ltd. Versatile Wires Ltd. Vidarbha Winding Wires Ltd.
Plant capacity: 6300 MT/AnnumPlant & machinery: 190 Lakhs
Working capital: -T.C.I: Cost of Project : 1126 Lakhs
Return: 45.00%Break even: 53.00%
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  • One Lac / Lakh / Lakhs is equivalent to one hundred thousand (100,000)
  • One Crore is equivalent to ten million (10,000,000)
  • T.C.I is Total Capital Investment
  • We can modify the project capacity and project cost as per your requirement.
  • We can also prepare project report on any subject as per your requirement.
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