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Sheet Metal Press Shop - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Sheet metal operations have been in existence since 8000 B.C. Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Due to its long history, sheet metalworking is, unfortunately, often seen as archaic and uninteresting. That metal sheets can be transformed with the aid of robust machines intonfancy consumer products with tight tolerances is inconceivable to many. Yet, sheet metal operations are used for producing both structural components and durable consumer goods. Nowadays, sheet metal parts are widely present in different daily life products. During the past decades, scientific research in the field of sheet metal operations has been booming and international conferences on different sheet metal topics attract numerous attendants. Both industry and the academic community recognize the importance of continuing improvement in sheet metal operations. Application Sheet and plate metal parts for consumer and industrial products such as: Automobiles and trucks, Airplanes, Railway cars and locomotives, Farm and construction equipment, Small and large appliances, Office furniture & Computers and office equipment. Advantages High strength, Good dimensional accuracy, Good surface finish, Relatively low cost, For large quantities, economical mass production operations are available. Uses The most common end uses for sheet metal have been electronic enclosures, such as personal computer housings or casings; roofing and roof drainage equipment; air conditioning ducts and stovepipes; sheet metal flooring and siding; awnings, canopies, cornices, and soffits; culverts, flumes, and irrigation pipes; and other or unspecified uses. These categories cover a myriad of products used by every industry, including aircraft manufacture (air cowls); building construction (siding, stove hoods, and gutters); heating, ventilation, and air conditioning (HVAC) applications (ducts, furnace flues); mineral processing (coal chutes); highway construction (guardrails); agriculture (irrigation pipes); business machines (computer casings); shipbuilding (ship ventilators); postal delivery (mailboxes); and food preparation (vats and bins). Market Survey According to industry statistics from Dun and Bradstreet, there were an estimated 5,917 establishments engaged in manufacturing sheet metal work for buildings (not including fabrication work done by construction contractors at the place of construction) in 2010 with revenues of more than $10.7 billion employing 115,838 workers. States with the highest concentration of establishments in this industry were California (15 percent), Texas (8 percent), Florida (5 percent), Pennsylvania (4 percent), and Ohio (4 percent). California accounted for the most sales, with $1.5 billion, followed by Texas with $898.5 million, New York with $593.3 million, and Illinois with $506 million. Sheet metal product sales are expected to account for 51.3% of industry revenue in 2012. Sheet metal products are used in virtually all phases of building construction and have many uses in improvements and repairs for existing structures. Sheet metal is used to install and maintain heating, ventilation and air-conditioning duct systems; roofs; siding; rain gutters; downspouts; and skylights. Some products manufactured in this segment include awnings, canopies, casings, chutes, ducts, furnace casings, gutters and ventilators Sheet metal demand in the US is forecast to cross $20 billion by 2016, following annual gains of over five percent from 2011. Cost Estimation Capacity : 900 MT/ Annum Mild Steel Sheet Products : 600 MT/ Annum MS Scraps : 300 MT/Annum
Plant capacity: -Plant & machinery: 6 Lakhs
Working capital: -T.C.I: Cost of Project : 217 Lakhs
Return: 25.00%Break even: 64.00%
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Transmission Towers & Tele Communication Towers With Galvanizing Plant - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study

A transmission tower (colloquially termed an electricity pylon in the United Kingdom and parts of Europe, an ironman in Australia, and a hydro tower in English Canada) is a tall structure, usually a steel lattice tower, used to support an overhead power line. They are used in high-voltage AC and DC systems, and come in a wide variety of shapes and sizes. Typical height ranges from 15 to 55 metres (49 to 180 ft), though the tallest are the 370 m (1,214 ft) towers of a 2700 metres long span of Zhoushan Island Overhead Powerline Tie. In addition to steel, other materials may be used, including concrete and wood. Uses & Applications The products of the Proposed Fabrication units are covered by Well designed and fabricated structures for a. state electricity boards for the purposes of electricity supply (i,e) a) power transmission Towers, TV and Radio Towers, Telecommunication Towers, b) Railway and Highway bridges etc. c. Industrial structures etc. Four major functions of transmission towers are in use: Suspension Towers, Terminal Tower, Tension Towers & Transposition Tower. Market Survey The Indian market has also the potential to generate 150,000 MW of hydro power. The Vadodara facility received fresh investments of about USD 30 mn with a scalable manufacturing capacity that currently stands at 1500 MW per annum. The Vadodara facility is one of the three largest hydro equipments facilities in the world. With the fast development of cellular telephones, a completely new segment of tower industry has emerged. The demand has increased precipitately in sympathy with the galloping expansion of cellular telephones.
Plant capacity: 24000 Mt/ Annum Plant & machinery: 163 Lakhs
Working capital: -T.C.I: Cost of Project : 833 Lakhs
Return: 45.00%Break even: 43.00%
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ALUMINA REFINERY - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue, Plant Layout

Alumina is a white granular material, a little less coarse than table salt, and is properly called aluminium oxide. Aluminium does not occur as a metal, but must first be refined from bauxite in its oxide form. Aluminium compounds make up 7.3% of the earth's crust, making it the third most common crustal element and the most common crustal metal on earth. Aluminium was first produced in 1808. There are three main steps in the process of aluminium production. First is the mining of aluminium ore, most commonly bauxite, referred to as bauxite mining. Second is the refining of bauxite into aluminium oxide trihydrate (Al2O3), known as alumina, and third is the electrolytically reduction of alumina into metallic aluminium. Development in the aluminium producing industry, consumption and environ¬mental implications are discussed, as well as aspects of future trends. This also includes the preceding processes of bauxite mining and alumina refining. Each of these process steps are described consecutively. Uses & Application Alumina is used in Gas laser tubes, Wear pads, Seal rings, High temperature electrical insulators, High voltage insulators, Furnace liner tubes, Thread and wire guides, Electronic substrates, Ballistic armor, Abrasion resistant tube and elbow liners, Thermometry sensors, Laboratory instrument tubes and sample holders, Instrumentation parts for thermal property test machines & Grinding media Market Survey The markets for alumina and aluminum have dramatic growth potential as a result of both significantly increased demand and political and environmental factors affecting supply. Global Alumina is perfectly positioned to capture the demand of independent aluminum producers as it builds the first green-field refinery to be constructed in Guinea in more than 40 years. Global aluminium prices are likely to go up in the wake of growing demand at domestic and international fronts, coupled with China's step to slash production of the metal. According to Harbor Intelligence, a global consulting firm specialising in forecasts for commodities, aluminium prices could touch $2,700 per tonne in the first half of the next year. In the middle of 2008, industry professionals forecast an increase in annual alumina demand of approximately 50 million metric tons, for a cumulative annual demand of 124 million metric tons, by 2017.
Plant capacity: 1800000 MT/ Annum Plant & machinery: 64454 Lakhs
Working capital: -T.C.I: Cost of Project : 79232 Lakhs
Return: 48.00%Break even: 46.00%
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INDUCTION WITH HOT ROLLING (CONCAST) AND STRUCTURE MILL - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Plant Layout

Steel is an alloy consisting mostly of iron, with a carbon content between 0.2 percent and 2.1 percent by weight, depending on the grade. Carbon is the most cost effective alloying material for iron, but various other alloying elements are used such as manganese, chromium, vanadium, and tungsten. Carbon and other elements act as a hardening agent, preventing dislocations in the iron atom crystal lattice from sliding past one another. Varying the amount of alloying elements and form of their presence in the steel (solute elements, precipitated phase) controls qualities such as the hardness, ductility, and tensile strength of the resulting steel. Steel with increased carbon content can be made harder and stronger than iron, but is also less ductile. Though steel had been produced by various inefficient methods long before the Renaissance, its use became more common after more efficient production methods were devised in the 17th century. Steel is one of the most recycled materials in the world, and, as of 2007, more than 78 percent of steel was recycled in the United States. In the United States, it is the most widely recycled material; in 2000, more than 60 million metric tons were recycled. The most commonly recycled items are containers, automobiles, appliances, and construction materials. For example, in 2007, more than 97 percent of structural steel and 110 percent of automobiles were recycled, comparing the current steel consumption for each industry with the amount of recycled steel being produced. A typical appliance is about 75 percent steel by weight and automobiles are about 65 percent steel and iron. The steel industry has been actively recycling for more than 150 years, in large part because it is economically advantageous to do so. It is cheaper to recycle steel than to mine iron ore and manipulate it through the production process to form new steel. Steel does not lose any of its inherent physical properties during the recycling process, and has drastically reduced energy and material requirements compared with refinement from iron ore. ? Uses & Applications Advantages of Stainless Steel Kitchenware and Houseware items:Corrosion Resistance: It gives protection against rust, Strength: Stainless steel has high tensile strength, excellent fatigue properties and good weld ability, Toughness and impact resistance: Stainless steel of certain grades has high toughness from elevated temperatures to sub zero temperatures, Formability: It is possible to bend and form different shapes, Heat resistance: Special high Chromium and Nickel alloyed grades resist high temperature and retain strength, Better aesthetic look: This is one single characteristic that scores over other materials, Low on maintenance: Stainless steel normally requires only a periodic wash with soap and water to maintain its original finish, Long term value: When the total life cycle costs are considered, stainless steel is often the least expensive material option available. Market Survey Under the dispensations of the government's Industrial Policy of the post liberalisation era, four steps changed the direction of the steel industry in India. These were (i) freedom to set up integrated steel plants in the private sector; (ii) placing imports of steel under OGL (open general licence); (iii) reduction of import duties on both steel and scrap; and (iv) decontrol of domestic prices. The comparative advantage of cheap and high quality iron ore and manganese, has been somewhat set off by the limited accessibility of the steel industry to the supply of coking coal. The adoption of the sponge iron route by the private sector integrated plants helped in circumventing the constraint, and at the same time, ushered in a technological revolution in the industry. As a result, India has come to enjoy a cost advantage compared to most countries. Not impressed by the Tenth Plan target of 38 mn tonnes (which was lower than 39 mn tonnes of the Ninth Plan), the Government of India had announced a new National Steel Policy in 2005. The policy aimed at achieving a production level of 110 mn tonnes in 2019 20, of which the domestic consumption was aimed to rise to 90 mn tonnes and exports to 26 mn tonnes. The industry was expected to register a CAGR of 7.3%, slightly higher than the 7% annual growth registered during the 15 year period ending 2004 05. According to a study carried out by the International Iron and Steel Institute, the demand in India is projected to a level of 180 mn tonnes by 2020. The domestic demand is based on the per capita consumption in the urban sector increasing from 77 kg to 165 kg in 2019 to 20 at an annual growth of 5%. Likewise the per capita consumption in rural areas was expected to rise from 2 kg per annum to 4 kg by the terminal year (a CAGR of 4.4%). India has one of the lowest consumption rate in the world around 33 kg per person to China's 200 kg, and South Korea's 900 kg. The thrust to an increased growth of over 7% is expected to be realised by a 13% annual increase in exports. Few Indian Major Players are as Under: A H W Steels Ltd. A S R Multimetals Pvt. Ltd. Aarti Steels Ltd. Adhunik Industries Ltd. Adhunik Power Transmission Ltd. Aditya Ispat Ltd. Arun Smelters Ltd. Ashiana Ispat Ltd. B S L Scaffolding Ltd. Balmukund Concast Ltd. Beekay Steel Inds. Ltd. Bhartia Commercial Co. Ltd. Chamundi Steel Castings (India) Ltd. Charminar Steels Ltd. Chase Bright Steel Ltd. Concast Ispat Ltd. Coromandel Steels Ltd. Deccan Alloys Pvt. Ltd. Delta Mechcons (India) Ltd. Dewas Metal Sections Ltd. Dhiraj Iron & Steel Ltd. Dina Iron & Steel Ltd. Divy Rollform Ltd. Dolphin Udyog Ltd. F A G Bearings India Ltd. G E I Power Ltd. G K Steel & Allied Inds. Ltd. Galaxy Bearings Ltd. Gangotri Iron & Steel Co. Ltd. Goa Ispat Ltd. Golden Rathi Star Inds. Ltd. Goyal Ispat Ltd. Grand Bright Bars Ltd. Handum Industries Ltd. Handum Iron & Steel Enterprises Ltd. Hans Metals Ltd. I S M T Ltd. India Steel Works Ltd. Indian Bright Steel Co. Ltd. Indian Steel Rolling Mills Ltd. Indo Germa Products Ltd. Indore Steel & Iron Mills Ltd. Indus Smelters Ltd. Ispat Profiles India Ltd. Jai Balaji Inds. Ltd. Jai Raj Ispat Ltd. Juhi Alloys Ltd. K R Steelunion Ltd. Kamal Sponge Steel & Power Ltd. Kanishk Steel Inds. Ltd. Kishan Chand Ferro Steels Pvt. Ltd. Kundil Ispat Ltd. M S P Steel & Power Ltd. Madhusudan Special Sections Ltd. Magnum Steels Ltd. Mahamaya Steel Inds. Ltd. Mahavir Rolling Mill Ltd. Mahavir Steel Inds. Ltd. Mahindra Sona Ltd. Man Structurals Ltd. Met Rolla Steels Ltd. Modern Steels Ltd. National General Inds. Ltd. O P Steels Ltd. P M P Steel Rolling Mills (Madras) Ltd. Peekay Re Rolling Mills Pvt. Ltd. Pondy Metal & Rolling Mills Pvt. Ltd. Premier Ispat Ltd. Prestige Stocks & Bonds Ltd. Punj Brothers Ltd. Purvi Bharat Steels Ltd. R H L Profiles Ltd. R K K R Steels Ltd. R P G Transmission Ltd. R R Ispat Ltd. R S Corporation Ltd. R S L Industries Ltd. (Duplicate Name, Uttar Pradesh) Rathi Bars Ltd. Rathi Rajasthan Steel Mills Ltd. Rathi Steel & Power Ltd. Rathi Super Steel Ltd. Richardson & Cruddas Ltd. Rukma Industries Ltd. S K M Alloys Pvt. Ltd. S P S Steels Rolling Mills Ltd. Shimoga Steels Ltd. Shobhagya Steels Ltd. Shree Sanyeeji Ispat Ltd. Shree Sidhbali Steels Ltd. Shree Vaishnav Ispat Pvt. Ltd. Shri Bajrang Alloys Ltd. Shri Bhagavati Bright Bars Ltd. Shri Ramrupai Balaji Steels Ltd. Shri Rathi Steels Ltd. Sirhind Steel Ltd. Somani Swiss Inds. Ltd. Sonal Vyapar Ltd. Southern Iron & Steel Co. Ltd. Sree Aravindh Steel Ltd. Supra Global Ltd. Suzlon Structures Ltd. Swetal Steel Inds. Pvt. Ltd. Tamil Nadu Small Inds. Corpn. Ltd. Testeels Ltd. Torus India Ltd. Trichy Steel Rolling Mills Ltd. Tungabhadra Steel Products Ltd. Unique Intercontinental Ltd. Upper India Steel Mfg. & Engg. Co. Ltd. Utkal Steels Ltd. V V S Alloys Ltd. Vaibhav Mercantile Ltd. Vijayaa Steels Ltd. Vinayak Steels Limited Vishwas Steels Ltd. Cost Estimation Capacity : 100 MT Steel Beam / day 75 MT Steel Channel / day 75 MT Steel Angels / day 50 MT Steel Bar / day
Plant capacity: -Plant & machinery: 970 Lakhs
Working capital: -T.C.I: Cost of Project : 4449 Lakhs
Return: 36.00%Break even: 52.00%
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ALUMINIUM INGOTS FROM USED BEVERAGE CANS - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities

A beverage can is a metal container designed to hold a fixed portion of liquid such as a carbonated soft drink, alcoholic beverage, fruit juice, herbal tea etc. Beverage cans are made of aluminium (75% of worldwide production) or tin plated steel (25% worldwide production). Worldwide production for all beverage cans is approximately 52 billion units. Aluminium recycling is the process by which scrap aluminium can be reused in products after its initial production. The process involves simply re melting the metal, which is far less expensive and energy intensive than creating new aluminium through the electrolysis of aluminium oxide (Al2O3), which must first be mined from bauxite ore and then refined using the Bayer process. Recycling scrap aluminium requires only 5% of the energy used to make new aluminium. For this reason, approximately 31% of all aluminium produced in the United States comes from recycled scrap. Used beverage containers are the largest component of processed aluminium scrap, with most UBC scrap manufactured back into aluminium cans. Ingot and billet play an integral part in the production of many aluminium products. Plate, sheet, foil, wire, rod, and bar products are all produced by pressing or rolling ingot and billet. Ingot and billet are cast from molten aluminium. In the cast house, crucibles of molten aluminium empty their silvery liquid either directly into molds or into a holding furnace where the metal is kept molten at temperatures between 1,200 and 1,500 degrees Fahrenheit. Alloying elements are then added. Most metal is cast by the direct chill (DC) process, which produces huge sheet ingot for rolling mills, round log like billet for extrusion presses, or square billet for production of wire, rod, and bar. Advantages The recycling of aluminium generally produces significant cost savings over the production of new aluminium even when the cost of collection, separation and recycling are taken into account Over the long term, even larger national savings are made when the reduction in the capital costs associated with landfills, mines and international shipping of raw aluminium are considered. Aluminium recycling is economically beneficial to both the aluminium and recycling industry. The capital cost for the production of recycled aluminium is already recognized to be far lower than making new aluminium. The financial benefit has also spurred the development of the recycling program. The price of scrap aluminium has fluctuated in the market but its traditionally high value has generated enough income. Aluminium cans are the poster child of the recycling movement. This is by far the most valuable component in the solid waste stream. The aluminium can is also the most recognized recyclable item among household waste. The aluminium beverage can is 100 percent recyclable into new beverage cans indefinitely demonstrating recycling at its finest. Aluminium can recycling helps fund the entire collection system. The aluminium can is the only packaging material that more than covers the cost of collection and re processing for itself. It also helps subsidize the collection of other recyclable materials. Market Survey The worldwide capacity to produce alumina was placed at around 80 mn tonnes in 2007 and was slated to touch 100 mn tonnes in 2010. Alumina accounts for about 22% of the cost in the production of aluminium. India's share in world aluminium market is estimated at around 3%. India ranks fifth in bauxite production after Australia (62 mn tonnes), Guinea (17.50 mn tonnes), Brazil (16.20 mn tonnes) and China (10.75 mn tonnes). With a total output of 9.25 mn tonnes, the country contributes about 6% of the world's total production of 159 mn tonnes, India holds the fifth position in reserves base and is ahead of China with 2300 mn tonnes. India ranked seventh in alumina production with a total output of 3 mn tonnes, a share of nearly 5% of the global production of 61 mn tonnes. However, internationally, the pattern of consumption is in favour of transportation, primarily due to large scale aluminium consumption by the aviation industry. White goods account for nearly 5% of aluminium consumption in the country. The products include electric fans, air conditioners, refrigerators and coolers. The white goods industry uses both extruded products and flats. In the transportation sector, aluminium is used for panelling, floors and windows. So far, it is not used for structural parts and bodies of automobiles. An Indian car uses only about 54 kg of aluminium against a global average of 100 to 110 kg. This sets the high potential for growth with the increase in the automobile sector. Demand for aluminium is estimated to grow at 4 to 6% per annum. The demand for the metal is expected to pick up as the scenario improves for user industries like power, infrastructure and transportation, which are all on the move.
Plant capacity: 1000 Kg /dayPlant & machinery: 109 Lakhs
Working capital: -T.C.I: Cost of Project : 298 Lakhs
Return: 24.00%Break even: 51.00%
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Low Carbon Ferro Manganese and Ferro Chrome (Through Alumina Thermic Process) - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials

Manganese is used in metallurgical industries in the form of ferro manganese. Ferro manganese contains about 80% Mn and 20% Fe. Generally ferro manganese is produced in blast furnace or an electric furnace. The high carbon ferromanganese (7.5% C, 74 80 % Mn & balance Fe) is the most important grade of ferromanganese Ferrochrome contains chromium as a major alloying element. With low carbon content, high chromium steels (Cr.12%) are corrosion resistant. With high carbon content, chromium raises the abrasion and wear resistance. Ferro Chrome is an alloy of chromium and iron containing between 50% and 70% chromium. The ferrochrome is produced by electric arc melting of chromites and chromium ore. Uses & Applications Low carbon Ferro manganese is widely used in the manufacturing of tool steels, alloys steel & structural steels. Ferromanganese is widely used in the manufacture of tool steels (up to 0.4% Mn) and structural steel (up to 0.6% Mn) and also of special steels with a high manganese content (up to 12 to 14%) Mn), as well as an alloying addition. Silcomanganese ferro alloy is used as a blocking agent to prevent the reaction of carbon & oxygen in Steel. Ferro Chrome with chrome content below 56% is known as charge chrome and produced from a chrome containing ore with a lower chrome content. Alternatively, High Carbon Ferro Chrome produced from higher grade ore, is more commonly used in specialist applications such as engineering steels. Low carbon Ferro Chrome is used during steel production to correct chrome percentages, without causing undesirable variations in the carbon or trace element percentages. Market Survey Ferro alloy production is very power intensive, forming between 40 and 70 per cent of the total production cost. Manganese alloy is the largest produced ferro alloy in the world with a share of about 41% of the global production of ferro alloys. Manganese is an essential requisite for iron and steel production owing to its capability for sulphur fixing, de oxidizing and good alloying properties. Production of manganese ferro alloys is dominated by China, accounting for nearly half of worldwide production from a combination of domestic low grade manganese ores and imported high grade ores. The steel industry also requires manganese alloys with less carbon than that contained in standard ferromanganese. India is exporting ferromanganese ferrosilicon & other bulk and noble alloys to various countries like FR Germany, France, Japan, Columbia, Dominican Rep, Italy, Netherlands, Singapore, Sweden, U.K., U.S.A. and others. The proposals are for an increase in import duties for all Ferro Alloys from 5% to 7.5% excluding Ferro Nickel and the removal of duties on raw materials and ores used in the production of Ferro Alloys. Current duties for imported raw materials range from 2.5% to 7.5%. There is a very good scope for this product and it is the appropriate time for new entrepreneurs to venture into this field. Few Indian Major Players are as under:to Aarti Steels Ltd. Adhunik Metaliks Ltd. Alok Ferro Alloys Ltd. Andhra Ferro Alloys Ltd. Bhaskar Shrachi Alloys Ltd. Bishwanath Ferro Alloys Ltd. Castron Technologies Ltd. Essel Mining & Inds. Ltd. Facor Alloys Ltd. Hindustan Ferro & Inds. Ltd. Hira Ferro Alloys Ltd. Idcol Ferro Chrome & Alloys Ltd. Jeypore Sugar Co. Ltd. M O I L Ltd. Maharashtra Elektrosmelt Ltd. Monnet Industries Ltd. Nagpur Power & Inds. Ltd. Natural Sugar & Allied Inds. Ltd. Nava Bharat Ventures Ltd. Orde Industries Ltd. R G Foundry Forge Ltd. Rohit Ferro Tech Ltd. S A L Steel Ltd. S K M Steels Ltd. Sarda Energy & Minerals Ltd. Shri Girija Smelters Ltd. Shyam Ferro Alloys Ltd. Sova Ispat Alloys (Mega Projects) Ltd. Sova Ispat Alloys Ltd. Srinivasa Ferro Alloys Ltd. T S Alloys Ltd. Tata Steel Ltd. Universal Ferro & Allied Chemicals Ltd. V B C Ferro Alloys Ltd. Visa Steel Ltd.
Plant capacity: 24 MT/DayPlant & machinery: 803 Lakhs
Working capital: -T.C.I: Cost of Project : Rs. 2695 Lakhs
Return: 56.00%Break even: 52.00%
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Automobile Brake Shoes - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Automobile manufacturers do not produce each and every item in the factory. Since the automobile vehicles are comprising of more than 5,000 parts. They are wholly depending upon the ancillary articles manufacturers. Their units are come under this section. These industries are on priority. Break shoe is used in the brake of an automobile. Automobile brakes require more attention than any other system in the vehicle. Equal emphasis is given to the clutch but it comes next. Brakes are mechanical devices using the force of friction to overcome motion. Any two surfaces in contract resist movement between the surfaces. The turning brake-drum (as well as the wheel) is slowed by applying pressure of a non-rotating band or shoe against it. An understanding of the requirement of braking systems of automobile vehicles requires knowledge of: - The purpose of brakes; an appreciation of their contribution to safety; recognition of the factors controlling the stop; an understanding of braking action and an appreciation of possible stopping distances. Uses and Applications Brake shoes are used in the brakes of automobile vehicles. This provides the base to the lining. This is the part, which feeds pressure and transmits this force to the lining by expansion. This is a very important part of the braking system. Due to the bad conditions of road in India this brake item will also increased in future since few more automotive industries are likely to be set in very near future. All the manufacturers of vehicles have to purchase this item from the manufacturer, so it will be profitable if start which a brake shoe manufacturing units. Market Survey The total market size of the auto-components industry is estimated at over Rs 700 bn. The overall investment in the components industry is estimated at Rs 288 bn. Having gained global recognition, the Indian auto components industry exports are placed at around USD 3.25 bn. The industry has largely succeeded in markets of Turkey, Russia, Iran and Uzbekistan. However, some MNCs in the USA and elsewhere also import Indian auto components. Most substantive component makers have taken ISO certification. The global players like Suzuki, Ford Motor, Hyundai, General Motors and others have promoted manufacturing capabilities either on their own or through joint ventures with Indian component manufacturers to meet their requirements. Few Major Players are as under:- A M C L Machinery Ltd. Arvind Engineering Works Ltd. Automotive Axles Ltd. Bosch Chassis Systems India Ltd. Brakes India Ltd. Bundy India Ltd. Echlin India Ltd. Mando India Ltd. S A B Wabco India Ltd. Special Engineering Services Ltd. T A L Precision Parts Ltd.
Plant capacity: Mild Steel Brake Shoe : 2625 Pcs./Day, Aluminium Brake Shoe: 875 Pcs./DayPlant & machinery: Rs.70 Lakhs
Working capital: -T.C.I: Cost Of Project : Rs.163 Lakhs
Return: 67.00%Break even: 41.00%
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Stainless Steel Tubes & Pipes by Extrusion and Pilgering Process - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study

Stainless Steel is a common name for metal alloys that consist of 10.5% or more Chromium (Cr) and more than 50% Iron (Fe). Although it is called stainless a better term for it is highly stain resistant. By adding chromium to low carbon steel gives it stain resistance. The three main types of stainless steels are austenitic ferritic and martensitic. These three types of steels are identified by their microstructure or predominant crystal phase. There are different grades and surface finishes of stainless steel to suit the environment the alloy must endure. Stainless steel is used where both the properties of steel and resistance to corrosion are required. Uses and Applications Stainless steels resistance to corrosion and staining, low maintenance and familiar lustre make it an ideal material for many applications. There are over 150 grades of stainless steel of which fifteen are most commonly used. The alloy is milled into coils sheets plates bars wire and tubing to be used in cookware cutlery household hardware surgical instruments major appliances industrial equipment (for example in sugar refineries) and as an automotive and aerospace structural alloy and construction material in large buildings. Storage tanks and tankers used to transport orange juice and other food are often made of stainless steel because of its corrosion resistance and antibacterial properties. Stainless steel pipes are used in petrochemicals fertilizers dairy industries power stations and nuclear plants. Other corrosion resistant applications as of food processing industry are also significant users. These pipes are used extensively by Nuclear Fuel Corporation. Market Survey Oil sector absorbs nearly 60% of seamless pipes while some 30% are consumed by bearings and boiler manufacturers. Apart from a number of small producers in the organized sector a very large informal sector also exists. The organised secondary sector contributes substantially to the total market requirement of all large dia pipe market. Steel tubes industry is poised for a 30% growth in the wake of a growing demand in the infrastructure construction sector mainly in scaffolding in buildings. The sector has grown dramatically in the recent past at a record 20% growth owing to several infrastructure projects lined up by the government and the private sector. Present Manufacturers C S T Valinox Ltd. Choksi Tube Co. Ltd. Interfit Techno Products Ltd. Kinjal Metals Ltd. Neeka Tubes Ltd. Prakash Steelage Ltd. Ratnamani Metals & Tubes Ltd. Suraj Chemtech Ltd. Tubetec Seamless Ltd.
Plant capacity: 10 MT/DayPlant & machinery: Rs.1148 Lakhs
Working capital: -T.C.I: Cost Of Project : Rs. 3194 Lakhs
Return: 19.00%Break even: 38.00%
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M.S. & H.T. Nuts & Bolts - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Fasteners have played a major role in the advancement of the human race since prehistoric days when the caveman used thongs to hold a rock into the split end of a stick to make the first axe. Since that day, the progress of fastening methods and devices includes: wooden pegs; wedges; the first iron nails; glue; rivets; welding; and today, a multitude of highly specialized fasteners that range from simple wooden clothespins to cap screws made from specialized materials for our space programs. Few of us realize the importance that fasteners play in our way of life. Less than $100 worth of fasteners represents the difference between a useless pile of parts and a finished automobile. A $75,000 crawler tractor would be nothing but scrap iron without a few hundred dollars worth of nuts and bolts. Without the variety of fastening devices available to industry, we would have to do without electricity, city water, natural gas, telephone, radios, television, refrigeration, transportation, canned and frozen foods, clothing, shelter, and in fact, almost every necessity and convenience we take for granted. Each year, the fastener industry uses over two million tons of steel to produce more than 200 billion fasteners in over two million different shapes and sizes. To keep pace with the rapidly expanding market and increasing demands for absolute reliability as well as availability, the fastener industry must continually develop new materials, improve its manufacturing and distribution techniques, invent ingenious new parts and gain prestige in the industrial world. All of these factors compile to make this one of the most complex industries that exist in the world today. Market Survey Fasteners Fasteners mainly cover nuts, bolts, screws, studs and rivets and are segmented between MS (mild steel) and HT (high tensile) fasteners. These fasteners are used in engineering systems. All types of fasteners, except high tensile and special type fasteners, are reserved for the SSI sector. MS fasteners are thus produced mostly in the unorganized sector, while HT fasteners are produced by the organized sector, as these require superior technology which SSI unorganized sector can ill afford. HT fasteners are either standard fasteners or specialized fasteners, the latter being made to meet specific customer requirements. The industry has been opened for FDI through direct route, if the products to be produced are not reserved for the SSI sector. The overall fasteners market is estimated at about Rs 28 bn. While the organized sector (HT fasteners) has a share of 65%, the balance of 35% is shared by unorganized sector and imports. The imports in 2006-07 were Rs 8 bn, leaving Rs 2 bn or 7% as the market for the unorganized sector in value terms. The market is heavily dependent on imports which have been growing at close to 28.5% in recent period. General application fasteners are catered to by the unorganized sector where brand and quality have little meaning and price is the main criteria for selection of the supplier. On the other hand, high tensile fasteners are used in engineering applications, such as in the automobile, industrial and other sectors. The varied applications include construction, railways and the domestic sectors. The market is made up of OEM or bulk market; and the replacement market (the retail market). Inspired by the phenomenal growth in the recent years, the leading companies in the organized market have regularly been expanding their capacities. The boom has been due mainly to the upswing witnessed by the automobile sector, the main end-user industry, accounting for almost half of the demand for fasteners. The four major companies in the industry are Sundaram Fasteners (turnover Rs 12 bn), the leader; Lakshmi Precision Screws (Rs 1.9 bn), Mahindra Fasteners (Rs 408.5 mn) and Sterling Tools (Rs. 1.4 bn). Other units, among the major players, are Guest Keen Williams (GKW) (Rs 1.1 bn), and Precision Fasteners (Rs 770 mn). Sundaram Fasteners (SFL) is a highly rated company and receives orders from overseas markets including those from the US (General Motors, in particular). The preferred products are radiator caps and powder metal parts. Sundaram also supplies cold extruded parts to Delphi Automotive Systems. Due to better product-mix in exports and increased sales volume, TVS group's blue chip, SFL has emerged as a strong player in the high-tensile fasteners market. Sundaram Fasteners invested Rs 250 mn for setting up of a greenfield manufacturing facility in China. The company's revenues from the Chinese operations account for 25% of its total exports. The manufacturing unit has an installed capacity of 6,000 tpa. Precision Fasteners leads in the industrial fastener segment. The company started manufacturing a wide range of Unbrako high-tensile fasteners' forged components in collaboration with SPS Technologies Inc of the US. Precision Fasteners had plans to enter the automotive fasteners market and was to target mainly the replacement segment. Its Silvasa plant capacity was being increased two-fold. Laxmi Precision Screws manufactures industrial as well as automotive fasteners. The company is reported to be developing indigenously cold-heading quality alloy steel wire which will improve the margins enabling it to compete globally. The company' turnover has progressively gone up from Rs 826 mn in 2000-01 to over Rs 1.90 bn in 2006-07 and to Rs 2.0 bn in the following year. The latter represents a growth of over 13.5% in 2006-07 and 5.8% in the following year. Few Indian Major Players are as under Agarwal Bolts Ltd. Atul Fasteners Ltd. Caparo Engineering India Pvt. Ltd. Coventry Spring & Engg. Co. Ltd. Dev Fasteners Ltd. G K W Ltd. G S Auto International Ltd. Indian Fasteners Ltd. Jaico Steel Fasteners Ltd. Lakshmi Precision Screws Ltd. Mohindra Fasteners Ltd. Patton Electro Ltd. Pooja Forge Ltd. Precision Fasteners Ltd. Quick Thread Pvt. Ltd. Rockfort Fasteners Ltd. Small Tools Mfg. Co. Of India Ltd. Sterling Tools Ltd.
Plant capacity: 600 MT/AnnumPlant & machinery: Rs. 207 Lakhs
Working capital: -T.C.I: Cost of Project: Rs 441 Lakhs
Return: 25.00%Break even: 54.00%
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Bimetallic and Sintered Bushes - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

The demand of the bushing is dependent on the various sectors like automobile, motors, home appliance etc. The Indian automobile market can be divided into several segments viz. two-wheelers (motorcycles geared and ungeared scooters and mopeds), three wheelers, commercial vehicles (light, medium and heavy), passenger cars, utility vehicles (UVs) and tractors. Demand is linked to economic growth and rise in income levels. A total of 13.4 mn two-wheelers were sold in India in FY12, a growth of a strong 14% over the previous year. Motorcycles accounted for 89% of the total two wheelers sold. The 3-wheeler segment was, however, at the receiving end as volumes dipped by 2%. The medium and heavy commercial vehicles (M/HCVs) segment saw its volumes grow by a tepid 8% during the fiscal after having grown by an impressive 32% in FY11. Riding the wave of structural changes taking place in the country, the tractor industry registered good growth in FY10 as well as FY11. This is the new emerging field and has a good domestic market. New entrepreneurs can well venture in this sector. Few Major Players are named as under: Electronica Machine Tools Ltd. G K N Sinter Metals Pvt. Ltd. G S Auto International Ltd. Holtzman Systems Ltd. Kanthal India Ltd. Menon Bearings Ltd. Trelleborg Automotive India Pvt. Ltd.
Plant capacity: 600000 Nos./AnnumPlant & machinery: Rs.102 Lakhs
Working capital: -T.C.I: Cost of Project: Rs.525 Lakhs
Return: 19.00%Break even: 42.00%
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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
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  • 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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