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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.

We can provide you detailed project reports on the following topics. Please select the projects of your interests.

Each detailed project reports cover all the aspects of business, from analysing the market, confirming availability of various necessities such as plant & machinery, raw materials to forecasting the financial requirements. The scope of the report includes assessing market potential, negotiating with collaborators, investment decision making, corporate diversification planning etc. in a very planned manner by formulating detailed manufacturing techniques and forecasting financial aspects by estimating the cost of raw material, formulating the cash flow statement, projecting the balance sheet etc.

We also offer self-contained Pre-Investment and Pre-Feasibility Studies, Market Surveys and Studies, Preparation of Techno-Economic Feasibility Reports, Identification and Selection of Plant and Machinery, Manufacturing Process and or Equipment required, General Guidance, Technical and Commercial Counseling for setting up new industrial projects on the following topics.

Many of the engineers, project consultant & industrial consultancy firms in India and worldwide use our project reports as one of the input in doing their analysis.

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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Electroplating of Gold & Their Chemical Treatment in Golden Colour on Silver Thread

Electroplating is the process of coating one metal or metal object with a very thin layer of another metal, typically by applying a direct electric current. This partially dissolves the metals and creates a chemical bond between them. The coating applied by electroplating is usually around 0.0002 inches thick. Gold plating, called gold electroplating, relies on a chemical process to combine various layers of metal into a solid piece with a layer of gold resting on the surface. In all gold plating, the part is polished and cleaned as thoroughly as possible before the electroplating process starts. Gold plating will look uneven and smudged if the surface is dirty, oily, scratched or otherwise damaged. Gold plating can be added to almost any metal, including brass, copper or nickel. Silver items can also be gold-plated.
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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C.I. Casting (Foundry) By Induction Furnace

An Induction Furnace is an electrical furnace in which the heat is applied by induction heating of metal. Induction furnace capacities range from less than one kilogram to one hundred tonnes, and are used to melt iron and steel, copper, aluminium, and precious metals. Cast irons as construction material are still maintaining the standard of usability, because they provide a wide range of usable properties and also because they require less expensive metallurgy, or technology, and in many cases they provide a more economically convenient solution.
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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Hard Chromium Plating

Chrome plating (less commonly chromium plating), often referred to simply as chrome, is a technique of electroplating a thin layer of chromium onto a metal object. The chromed layer can be decorative, provide corrosion resistance, ease cleaning procedures, or increase surface hardness. Sometimes, a less expensive imitator of chrome may be used for aesthetic purposes. Hard chrome plating demonstrates excellent hardness and lubricity, and is the premier engineering choice to reduce friction, minimize wear and prevent galling. These characteristics are applicable for critical engineering applications, including: machine tool cutting surfaces, cylinder bores, strut rods, crankshafts and hydraulic shafts. Hard chrome is also applied to molds because of its low surface energy and resultant release properties. Chem Processing can hard chrome plate steel, aluminum, or copper materials, as well as many exotic alloys. Hard chrome plating is an electrolytic process in which chromium is deposited onto a metal substrate giving it enhanced properties for durability, wear and hardness. The electrolytic process is generally achieved by passing an electric current through a chromic acid solution (called an electrolyte bath) between two electrodes, one of which will be the substrate which is to be plated. The demand for functional chrome plating is mainly driven by the growth in commercial and passenger vehicle industry. Increased demand from the commercial vehicles on account of factors such as high strength and improved processes is expected to have positive impact on the market over the next nine years. Fair rate of product replacement coupled with high margins on sales and installation is expected to drive the global automotive chrome market. Chromium plating process involves different steps which include degreasing, cleaning dirt & impurities, different types of pretreatment varying according to substrate material.
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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Metal Polish Soap

Metal Polishing Soap can be used for final polishing in all Aluminium and Stainless steel products. Metal polishing compounds are ideal for high quality polishing on stainless steel, aluminium and other non-ferrous metals. However, our metal polishing compounds are extremely effective on carbon, steel, chrome and plastics. There are several different types of metal polish in the huge world of automotive detailing. Apart from the polish for paintwork there is also polish specifically for metal. These are mostly used for chrome bumpers, chrome trims, metal hubcaps, untreated metal wheels, exhausts and even engine parts. Metal polishing cleans, brightens, and restores solid or plated items made of gold, silver, stainless steel, brass, copper, aluminum, nickel, chrome, or other metals and alloys. Achieving a smooth and shiny finish requires tools like fixed, tabletop, or hand-held grinders, polishers and buffers. Solvents, acids, and various abrasive materials are used to degrease, clean, buff, and polish metals. The global metal finishing equipment market is growing, due to increasing need for wear resistant, durable and long lasting metal products, up surging demand from developing countries, and growth of automotive and steel industries. The growth of environment friendly electro less plating and consumers’ shift from traditional solvent borne technologies to newer technologies, are providing ample opportunities for the growth of the global metal finishing equipment market in the coming years. Asia-Pacific dominates the global metal finishing equipment market, due to growing steel and automobile industries in the developing countries of the region.
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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Galvanising of Zinc (By Electrical Process)

The Zinc Galvanizing process starts by carefully cleaning the surface of the steel by hoisting it from the Black area by a 2MT EOT crane and immersing it in a degreasing tank filled with an acid based degreaser after which it is cleansed twice in pickling tanks filled with 15% con. Zinc Galvanizing plants demand for lot of participation by the promoters as it has to stabilize the plant processes and parameters and involve the plant management to achieve the targets aimed.
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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Aluminium Anodizing Plant

Amorphous aluminum oxide (alumina, Al2O3) forms in a layer 2-3 nm thick when bare aluminum is exposed to oxygen. Aluminium anodizing is an electrochemical process in which an oxide (anodic) layer is chemically built on the surface of the metal. This oxide layer acts as an insulator and can be dyed in a wide variety of colors. Anodizing provides surface corrosion protection along with an excellent substrate for decorative finishes. Anodizing is a process for producing decorative and protective films on articles made from aluminium and its alloys. It is essentially a process where a thick film of aluminium oxide is built up on the surface of the aluminium through the use of a direct current electrical supply. Anodizing is an electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant, anodic oxide finish. Aluminium is ideally suited to anodizing, although other nonferrous metals, such as magnesium and titanium, also can be anodized. While anodizing aluminium allows the metal to keep its natural appearance, the pores in the protective oxide layer also help to provide a better surface for the adhesion of paints and glues. Anodized aluminium parts are commonly found in aircraft and architectural components, as well as consumer goods such as appliances (refrigerators, microwaves, and barbecues), sporting goods (baseball bats, golf carts, and fishing equipment) and electronics (televisions, smartphones, and computers).
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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Aluminium Anodizing Plant

Amorphous aluminum oxide (alumina, Al2O3) forms in a layer 2-3 nm thick when bare aluminum is exposed to oxygen. Aluminium anodizing is an electrochemical process in which an oxide (anodic) layer is chemically built on the surface of the metal. This oxide layer acts as an insulator and can be dyed in a wide variety of colors. Anodizing provides surface corrosion protection along with an excellent substrate for decorative finishes. Anodizing is a process for producing decorative and protective films on articles made from aluminium and its alloys. It is essentially a process where a thick film of aluminium oxide is built up on the surface of the aluminium through the use of a direct current electrical supply. Anodizing is an electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant, anodic oxide finish. Aluminium is ideally suited to anodizing, although other nonferrous metals, such as magnesium and titanium, also can be anodized. While anodizing aluminium allows the metal to keep its natural appearance, the pores in the protective oxide layer also help to provide a better surface for the adhesion of paints and glues. Anodized aluminium parts are commonly found in aircraft and architectural components, as well as consumer goods such as appliances (refrigerators, microwaves, and barbecues), sporting goods (baseball bats, golf carts, and fishing equipment) and electronics (televisions, smartphones, and computers).
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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Zinc Brightener

These products are highly admired in the market for their attractive features. The brightener is widely used in chemical and other industries in the galvanization process. The brightener is used to coat steel and other metals to prevent those from being corrode. Apart from this, the brightener is inspected on various quality controllers to eradicate all flaws which are used in Fasteners Industry. Features: • Long shelf life • Highly pure • Free from impurities • Properly packed • Non toxic • Easy to use
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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Porcelain Insulators

An electrical insulator is a material whose internal electric charges do not flow freely, and therefore make it nearly impossible to conduct an electric current under the influence of an electric field. This contrasts with other materials, semiconductors and conductors, which conduct electric current more easily. The property that distinguishes an insulator is its resistivity; insulators have higher resistivity than semiconductors or conductors. Low-tension insulators are used for A.C. & D.C. power supplies of not more than 600 volts. Low tensions insulators are manufactured in both glazed and unglazed insulators are quite satisfactory. Insulators required for use in humid atmosphere are invariably glazed. Glazed insulators are used in lighting arrestors in radio receivers, telephone and utility outfits and neon signs. Some L.T. insulators like nail knobs, tubes & cleats are glazed on one side. Voltage above 1000 Volts is generally considered as high tension for long distance Electric power transmission; high voltage is essential because it reduces the cross/section and, therefore, the weight of the conductor required. Porcelain insulators are suitable for high tension transmission & distribution are required to be effective at high voltages and under extreme climate conditions of rain, snow, high wind of soaring heat. The global Porcelain Insulators Market has grown significantly over the past few years and is anticipated to expand at a rapid pace till 2026. This market study provides an in-depth assessment on market size and year on year growth of global Porcelain Insulators Market in terms of revenue, various levels of in-depth market segmentation, market dynamics which comprises of the demand side, supply-side and economy side drivers, market restraints, challenges and opportunities and trends which are prevailing in this market and impacting the growth of the market. Worldwide Porcelain Insulators Market highlights its existing absolute $ opportunity. Further, this market is likely to achieve considerable absolute $ opportunity by the year 2026 as compared to the value achieved in the year 2018. Growing investments toward the expansion of Transmission & Distribution (T&D) infrastructure to support the ongoing large-scale renewable power integration will propel the high voltage porcelain insulators market growth. Rising focus of utilities toward strengthening and modernization of grid networks along with introduction of ambitious renewable integration target of governments will further complement the industry landscape. Surging investments toward the refurbishment and replacement of aging electrical infrastructure across the developed economies coupled with the growing adoption of smart grid technologies will drive the porcelain insulators market growth. As per the U.S. Energy Information Administration (EIA), in 2017, major utilities across the country had invested over USD 50 billion toward expansion and strengthening of nation’s distribution networks. An electrical insulator is a material whose internal electric charges do not flow freely, and therefore make it nearly impossible to conduct an electric current under the influence of an electric field. This contrasts with other materials, semiconductors and conductors, which conduct electric current more easily. The property that distinguishes an insulator is its resistivity; insulators have higher resistivity than semiconductors or conductors Few Indian major players are as under Meister International National Switchgears ZPE ZAPEL Aditya Birla Insulators Power-grid Switchgears PPC Insulators Yigang Precision Ceramics
Plant capacity: Porcelain Insulators:500.0 MT / dayPlant & machinery: 695 lakhs
Working capital: -T.C.I: Cost of Project:Rs 2804 lakhs
Return: 29.00%Break even: 50.00%
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Start your own business in Porcelain Insulators. Most Profitable Opportunities for Startups.

Start your own business in Porcelain Insulators. Most Profitable Opportunities for Startups. An electrical insulator could be a material within which the electron doesn't flow freely or the atom of the insulator have tightly bound electrons whose internal electric charges don't flow freely; little electric current can flow through it underneath the influence of an electric field. This contrasts with different materials, semiconductors and conductors that conduct electric current a lot of easily. The property that distinguishes an insulator is its resistivity; insulators have higher resistivity than semiconductors or conductors. The foremost common examples are non-metals. Related Projects: - Electrical, Electronic Industries and Power Projects Insulators are utilized in electrical equipment to support and separate electrical conductors while not permitting current through themselves. An insulating material utilized in bulk to wrap electrical cables or different instrumentation is named insulation. The term insulator is additionally used a lot of specifically to refer to insulating supports used to attach electric power distribution or transmission lines to utility poles and transmission towers. They support the load of the suspended wires while not permitting this to flow through the tower to ground. When a material's electrons have very little freedom to maneuver from atom to atom, the material functions as an electrical insulator. Samples of this include glass, rubber, plastic and air – the previous 3 of which are often utilized in electronic equipment and wiring. Rubber, specifically, is usually used as a wearable insulator to shield electricians and alternative specialists from shocks that would be dangerous or deadly while not protection. At an equivalent time, plastic is used within the coating of power cables to confirm that electricity flows solely from the ability source to your electric devices. In power generation, electric cables are protected from the metal of the towers that carry them with large glass insulators. Related Projects: - Renewable Energy Sector Porcelain insulators are suitable for high tension furthermore as low tension transmission & distribution are needed to be effective at high voltages and underneath extreme climate conditions of rain snow, high wind of soaring heat. The foremost common in use are suspension kind and pin type. The top kind material is used on all distribution lines and on low voltage transmission lines. The most advantage of the pin kind insulator is that it's the cheaper insulator. The foremost usual material for outdoor insulators is porcelain, though toughened glass has recently been developed. USE OF INSULATORS ? Pin insulators are used in transmission up to 33 kv system. ? Solid post insulators is used for substation requirements. ? Suspension insulators are also used in transmission above 33 kv. ? Hollow insulators are used for making of circuit breakers, Current transformers, Potential transformers, Bushings, Lightning arrestors. PROCESS OF MANUFACTURING Main raw materials like china clay, ball clay, quartz, feldspar, plastic fire clay are used for the preparation of body. Materials like whiting, barium carbonate, zinc oxide etc. are used for the preparation of glazes. The non-plastic raw materials are ground in ball mill to the fineness of 100-120 number mesh and water is added in desired proportion. China clay and other soft clays with 0- 40% water are blunted in the blunter and sieved through 120 No. mesh and then passed through electromagnet in order to remove the iron particles. Books:- BOOKS & DATABASES Both slurries are mixed proportionately in the agitator tank. The slurry from the agitator tank is passed through filter press for dewatering to make cakes. L.T. Insulators like pin, shackles etc. are made by pressing or throwing process followed by turning on leather hardening. For making the electrical pressed porcelain items, the cakes are dried and powdered in a disintegrator. Dry broken green articles are also mixed with this body with approx. 6% water and 3% oil is mixed to form consistent and uniform granules. The prepared mass is again passed through a sieve granulator, so that any lump formed during mixing is broken to form granules. The mass is then pressed into shapes in a pillar press/toggle press fitted with dies of desired shapes. The articles are then dried and finished. The articles are glazed, if required and then fired at the temperature of about 1280oC in a shuttle kiln. The articles are taken out from the kiln are sorted and packed for selling. TYPES OF INSULATORS:- 1) Pin insulators. 2) Solid post insulators. 3) Suspension insulators. 4) Hollow insulators. 5) Long rod single piece porcelain insulators. MARKET OUTLOOK Factors similar to increase in infrastructural investment in various countries followed by favorable government regulations fuel the demand for the worldwide insulator market. To boot, ceramic insulators are mainly most popular over its glass counterparts as they possess advantages like a lot of proof against external harm from installation & shipping and deliver higher performance in wet conditions. Additionally, it also has high thermal shock resistance. Of these factors are expected to boost the growth of the market throughout the forecast period from 2019 to 2026. However, increase in incidence of pollution flashover accident is expected to hamper the market growth. However, shift in consumer preference toward composite insulator because of its better performance compared to insulators, is another factor that hampers the growth of the market. Further, on the opposite hand, rise in investments in numerous developing countries serves as an opportunity for the market. Related Videos: - Electrical, Electronic Industries and Power Projects Increasing investments toward the modernization of aging grid infrastructure along with fast urbanization can drive the India electrical insulators market. Rising investments for the growth of electric networks along with investment targets supporting the whole price chain of power transmission, generation, and distribution can further propel the trade dynamics. India transformers electric insulators market will witness growth on account of escalating electric infrastructure spending coupled the ongoing industrial expansions being carried out in the country. Increasing investments made by government authorities for the reduction of transmission losses will further complement the industry growth. INCREASING DEMAND FOR CERAMIC/PORCELAIN TYPE INSULATORS The Ceramic/porcelain type is expected to dominate the electric insulator market in 2019. Electrical insulators made of ceramic are primarily used in high voltage insulating systems. Furthermore, these insulators can be custom manufactured to be applied in high-temperature resistors. The ceramic insulators usually have a higher dielectric constant, which does not vary much with varying temperature, unlike glass, which conducts more electricity at elevated temperatures, i.e., the dielectric constant of glass varies with temperature. The demand for ceramic electrical insulators is expected to be driven by the expanding transmission and distribution network, supported by growing energy consumption, penetration of renewables in the global energy mix, among various other factors. It is expected that by 2022, the renewable energy capacity growth would be as high as 90%, out of which a significant fraction is likely to come from big utility-scale projects, which, in turn is a positive indicator for the transmission and distribution market, and consequently a bright market outlook for the ceramic electric insulators in the coming years. ASIA PACIFIC: THE FASTEST GROWING MARKET FOR ELECTRIC INSULATOR MARKET The Asia Pacific is estimated to be the fastest growing market for electric insulator market in 2023 and is projected to grow at the highest CAGR during the forecast period. Increase in population, urbanization, and the growth of the industrial sector have increased the demand for power in countries such as China and India. The government of Asia Pacific countries is planning to develop more electrical grid and power generation capacity, which would further boost the demand for insulator in the region. Therefore, increasing demand for power and up gradation of existing electrical infrastructure is expected to boost the electric insulator demand in the region. KEY PLAYERS Meister International National Switchgears ZPE ZAPEL Power-grid Switchgears PPC Insulators Yigang Precision Ceramics ABB Ltd. (Switzerland), Aditya Birla Nuvo Ltd. (India), General Electric, Siemens AG (Germany), Tags:- #porcelaininsulators #porcelaininsulator #electricinsulators #insulator #insulators #porcelain #ceramicinsulator #ceramicinsulators #porcelainbox #GlassInsulators #DetailedProjectReport #businessconsultant #BusinessPlan #feasibilityReport #NPCS #industrialproject #entrepreneurindia #startupbusiness #startupbusinessideas #businessestostart #startupideas #BusinessFeasibilityStudies #technologyindustry #feasibilityReport
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Return: 1.00%Break even: N/A
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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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