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Electroplating, Metal Polishing, Anodizing, Phosphating, Metal Finishing and Powder Coating projects

Surface finishing is a broad range of industrial processes that alter the surface of a manufactured item to achieve a certain property. Currently, the trend is towards surface treatments. Surface engineering techniques are generally used to develop a wide range of functional properties, including physical, chemical, electrical, electronic, magnetic, mechanical, wear-resistant and corrosion-resistant properties at the required substrate surfaces. In general, coatings are desirable, or even necessary, for a variety of reasons including economics, material conservation, unique properties, or the engineering and design flexibility which can be obtained by separating the surface properties from the bulk properties. Some of common metal surface finishing technology are electroplating, electroless nickel plating, aluminium anodizing and dying, black oxidizing of copper and steel, conversion coating and passivation, pickling, heat treatment, electropolishing etc.

Electroplating is the process of applying a metallic coating to an article by passing an electric current through an electrolyte in contact with the article, thereby forming a surface having properties or dimensions different from those of the article. Essentially any electrically conductive surface can be electroplated. Special techniques, such as coating with metallic-loaded paints or silver-reduced spray, can be used to make nonconductive surfaces, such as plastic, electrically conductive for electroplating. The metals and alloy substrates electroplated on a commercial scale are cadmium, chromium, cobalt, copper, gold, indium, iron, lead, nickel, platinum group metals, silver, tin, zinc, brass, bronze, many gold alloys, lead-tin, nickel-iron, nickel-cobalt, nickel-phosphorus, tin-nickel, tin-zinc, zinc-nickel, zinc-cobalt, and zinc-iron. Electroplated materials are generally used for a specific property or function, although there may be some overlap, e. g., a material may be electroplated for decorative use as well as for corrosion resistance.

Electropolishing is used in the pharmaceutical, electronic, food, beverage, automotive, aerospace and many other industries. Pickling is the removal of oxide layers resulting from welding and heat-treating. Pickling or chemical cleaning is the chemical cleaning of metallic surfaces in order to remove impurities, stains or scale with an acidic solution. Anodizingis an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of metal parts.

With the growth in infrastructure, India will need huge amounts of metal. Aluminium is used in various sectors such as transportation, packaging, building/construction and electricity. Globally, automotive, packaging and construction sectors are the major end users of aluminium, while in India the power sector consumes most followed by automotive and housing sectors. The sector wise consumption break -up as follows: electrical-64 per cent, transport-18 per cent, packaging-4 per cent, industrial machinery-3 per cent, consumer durables-3 per cent, and steel sweetening, power and chemicals -11 per cent. There is no doubt that Indian infrastructure is poised for a great leap forward. The surface finishing industry will play an important role in constructing the Indian infrastructure.

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Aluminium Anodizing Unit

Aluminium and most aluminium alloys have high corrosion resistance because of protective oxide films thatformonthesurface when the metal is exposed to air. Anodizing of aluminium is the process by which the thick layer of aluminium oxide is made on the upper surface of the aluminium articles. The oxide film, is formed automatically about 0.1-0.4 x 106 inches or 0.25 1 x 10-2microns. Micron is a unit used to measure the film thickened i.e. very small thicknesses. Anodic oxidation or anodizing is an electrolytic process for thickening this naturally occurring film several hundred times or more. This thicker oxide film has properties that open new fields of application to aluminium and hence its suitability in many existing uses. The anodic film is chemically stable and abrasion resistance. It also has a high dielectric strength. Valuable in some application where aluminium used as an electrical conduct. The film may be retain high reflectivity, while its microcell structure enables it to absorb dyes to give a wide range of decorative effects. It also forms an excellent key for plain coatings. Anodizing is accomplished by immersing the aluminium into an acid electrolyte bath and passing an electric current through the medium. A cathode is mounted to the inside of the anodizing tank; the aluminium acts as an anode, so that oxygen ions are released from the electrolyte to combine with the aluminium atoms at the surface of the part being anodized. Anodizing is, therefore, a matter of highly controlled oxidation the enhancement of a naturally occurring phenomenon. The global anodized aluminium components for beauty packaging market is estimated to reach US$ 5,450.6 million by 2026 from US$ 3,676.6 million in 2018, and is projected to exhibit a CAGR of 5.8% over the forecast period (2019–2026). Key drivers such as shifting consumer preference towards sustainable, eco-friendly & aesthetically appealing packaging material are expected to positively impact demand for anodized aluminium components during the forecast period. However, high cost of aluminium compared to other materials such as tinplate, steel is estimated to be a major factor restraining growth of the market in the near future. Anodized aluminium is used in commercial and consumer applications in industries such as the transportation and construction. It is also used in home decors and electrical appliances. In addition, it is employed in satellites to provide protection from debris. Therefore, the global anodized aluminium market is likely to experience a promising growth. Aluminium is used in a huge variety of products including cans, foils, kitchen utensils, window frames, beer kegs and aero plane parts. This is because of its particular properties. It has low density, is non-toxic, has a high thermal conductivity, has excellent corrosion resistance and can be easily cast, machined and formed. It is also non-magnetic and non-sparking. It is the second most malleable metal and the sixth most ductile. Due to the fact that consistent growth of Indian economy at a rate of 8%, the demand for metals, used for various sectors, is also on the higher side. As a result, the Indian Aluminium Industry is also growing consistently as in the year 2009 the aluminium industry in India saw a growth of about 9%. Indian Aluminium Industry is a highly concentrated industry with the top 5 companies constituting the majority of the country's production.With the growing demand of Aluminium, the industry is also growing at an enviable pace. In fact, Aluminium production in India is currently outpacing the demand. Although India's per capita consumption of Aluminium stands too low (under 1 kg) as compared to the per capita consumptions of other countries like US & Europe (range from 25 to 30 kgs), Japan (15 kgs), Taiwan (10 kgs) and China (3 kgs), the demand is growing gradually. In India, the industries that require Aluminium Reserves most include power (44%), consumer durables, transportation (10-12%), construction (17%) and packaging, etc. The global requirement is estimated at around 7.4 million tons, against the consumption in India as only around 110,000 tons. India's share in the global downstream sector is low as compared to other developed countries.India has nearly 10% of the world's bauxite reserves and a growing aluminium sector that leverages this. Demand in the domestic market is expected to grow by 8-10; India is expected to have an installed aluminium capacity of 1.7 to 2 million tons per annum by 2020. Few Indian major players are as under Adishakti Alloys Pvt. Ltd. Alexcon Extrusions Ltd. Alom Extrusions Ltd. Alufit (India) Pvt. Ltd. Alumayer Systems Pvt. Ltd. Aluminium Profiles Ltd. Autoneum India Pvt. Ltd Bhoruka Extrusions Pvt. Ltd.
Plant capacity: Aluminium Anodized Articles: 10 MT / dayPlant & machinery: Rs 66 lakhs
Working capital: -T.C.I: Cost of Project: Rs 257 lakhs
Return: 26.00%Break even: 57.00%
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Catenary Wires and Conductors used in Railway Electrification

Catenary wire (also called a messenger wire) has closely spaced drops which support the actual contact wire. The messenger (or catenary) wire needs to be both strong and have good conductivity. They used multi-strand wires (or cables) with 19 strands in each cable (or wire). Copper, aluminium, and/or steel were used for the strands. All the 19 strands could be of the same metal or some strands could be of steel for strength with the remaining strands of aluminium or copper for conductivity. Another type looked like it had all copper wires but inside each wire was a steel core for strength. The steel strands were galvanized but for better corrosion protection they could be coated with an anti-corrosion substance. The Catenary wire comprises 19 strands of cadmium copper, each strand of 2.10 mm dia, with overall dia of 10.5 mm having about 80% conductivity and 65 sq. mm cross-sectional area. The contact wire is a solid hard drawn grooved electrolytic. Copper of 12.24 mm dia and 107 sq. mm cross-sectional area. The total current carrying capacity of both wires is 600 Amps. The condemning size of contact wire is 8.25 mm. The wires and cable industry in India has come a long way, growing from being a small industry to a very large one, over the past decade. With the segment comprising nearly 40 per cent of the electrical industry in India, the increasing demand for power, light and communication has kept demand for wires and cables high. Growing at a CAGR of 15 per cent, boosted by momentum in the power and infrastructure segments. The present estimated per capita consumption is only about 0.5 kg. As GoI is focusing on ´Make in India´, the industry can grow at similar rate for the next five years. The India structured cabling market was valued at $419.4 million in 2017 and is forecasted to witness a CAGR of 12.9% during 2018–2023. Growing demand for copper cables, surging data center market, increasing number of product launch activities, and rising demand for better bandwidth are supporting the structured cabling market growth in India. Growing domestic market, priority for infrastructure development, improved life-style and newer opportunities, have propelled the Indian copper industry, specially for wires and cables. The growing trend in building, construction and automobile sectors is expected to keep demand of copper high. Understanding the copper technology involved in copper production, exploration, mining, and the uses of copper, as well as the global industry structure would impact copper mining, the environment, the various markets of copper, etc. The industry is affected by the price trends of copper, market performance, import/export scenario, the physical market trends, demand for copper, and of course, a market forecast. According to their Indian Electrical Equipment Industry Mission Plan 2012-2022, the government has planned to make India the country of choice for the production of electrical equipment and reach an output of $100 billion by balancing exports and imports. Requirement of electrical equipment is one of the most important inputs for the development of the power sector. The user enjoys right for safe and quality products and should be quality conscious while selecting the make. As a whole any entrepreneur can venture in this project without risk and earn profit. Few Indian major players are as under Elite Conductors Ltd Dharmadeep Powerdive Inds. Ltd Copper Semis Pvt. Ltd. Chandra Metals Pvt. Ltd. G K Winding Wires Ltd Grid India Power Cables Pvt. Ltd. Hindustan Transmission Products Ltd K E C International Ltd. M E W Electricals Ltd.
Plant capacity: Catenary Wire (Hard Drawn Stranded Magnesium Copper Conductor) Size 24 (7/2.10 mm): 5.3 MT / Day Catenary Wire (Hard Drawn Stranded Magnesium Copper Conductor) Size 24 (19/2.10 mm): 5.3 MT / Day Catenary Wire (Hard Drawn Plant & machinery: Rs 260 lakhs
Working capital: -T.C.I: Cost of Project: Rs 871 lakhs
Return: 30.00%Break even: 55.00%
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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.
  • Caution: The project's cost, capacity and return are subject to change without any notice. Future projects may have different values of project cost, capacity or return.

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